两道次渐进成形表面粗糙度的预测和分析

Prediction and analysis of the surface roughness of double-stage incremental forming

为了研究两道次渐进成形的表面质量,采用响应面法来分析和优化两道次渐进成形的整体表面粗糙度.首先,通过Box-Behnken设计方法制定以成形角α、道次间隔角度Δα、层间距Δz和进给速度V为主要研究参数的试验计划.其次,建立了四个工艺参数与成形件表面粗糙度间的数值模型,并结合实验与方差分析(ANOVA)验证了数学模型的准确性.然后,利用数值模型探讨四个参数及其相互作用对表面粗糙度的影响情况.最终得出:层间距、道次间隔角度、成形角及进给速度对表面粗糙度的影响依次减弱.当V增加时,粗糙度值先减小再呈增加趋势;当Δz,Δα和α增加时,表面粗糙度值随之增加.此外,通过优化提出了获得最优表面质量的参数组合,并通过实验验证了这组参数组合的优越性.

To research the surface quality of double-stage incremental forming,response surface method was adopted to model and optimize the overall surface roughness in double-stage incremental sheet forming（DS-ISF）.First,the Box-Behnken design approach was used to develop the experimental plan where four main process parameters（wall angelα,angle intervalΔα,step sizeΔz and feed rate V）were considered.Second,a mathematical model between process parameters and roughness was established and verified by experiments and analysis of variance（ANOVA）.Then,the effect of these parameters and their interactions on surface roughness were investigated by adopting ANOVA technique.It is found that step size has the maximum influence on the roughness,followed by angle interval,wall angel and feed rate.Roughness value first decreases and then increases with the increase of V,and increases with the increase ofΔz,Δαandα.In addition,a optimal set of parameters was provided after verified.