基于多向无模渐进成形的薄板柔性卷边工艺

Flexible curling of thin-walled sheet based on multi-directional incremental forming process without die

传统的薄板卷边工艺难以满足个性化定制、新品开发等的需求,为此研究了一种基于多向无模渐进成形的薄板柔性卷边新方法,利用改进的工具头对1 mm厚的Al6061铝板和0.27 mm厚的SUS 304不锈钢板进行了卷边实验和数值模拟,探讨了加工工艺参数对力与变形的影响,分析了典型缺陷的形成与控制方法。研究表明,该方法能够实现板料的柔性卷边成形而无需专用模具,大大扩展了渐进成形的加工范围。对于渐进卷边过程中可能出现翘曲、折弯、表面划痕以及因＂端部效应＂引起的缺陷等,可以通过减小进给量、增加预成形、改善润滑条件、改进工具头形状等方法对变形加以控制,从而消除成形缺陷。

Traditional curling technologies of thin-walled sheet can hardly meet the requirements of personalized needs and development of new products. Therefore,a new method of flexible curling of thin-walled sheet was studied based on multi-directional incremental forming process without die. Then,aluminum alloy Al6061 plate with thickness of 1 mm and stainless steel SUS 304 plate with thickness of0. 27 mm were conducted by curling experiments and numerical simulation through improved tool head,and the influences of processing parameters on force and deformation were analyzed. Furthermore,the formation and control method of typical defect was discussed. The research shows that this method can realize the flexible curling of sheets without die and greatly extend the forming range of incremental forming. And warping,buckling,surface scratch and defects caused by the end effect during the processes can be controlled by reducing feed rate,adding preforming,modifying lubricating condition and changing tool head shape.