Thin-walled aluminum alloy tube numerical control （NC） bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of...Thin-walled aluminum alloy tube numerical control （NC） bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of the parameters was proposed based on the finite element （FE） simulation, and the significance analysis of the processing parameters on the forming quality in terms of the maximum wall thinning ratio and the maximum cross section distortion degree was implemented using the fractional factorial design. The optimum value of the significant parameter, the clearance between the tube and the wiper die, was obtained, and the values of the other parameters, including the friction coefficients and the clearances between the tube and the dies, the mandrel extension length and the boost velocity were estimated. The results are applied to aluminum alloy tube NC bending d50 mm×1 mm×75 mm and d70 mm×1.5 mm×105 mm （initial tube outside diameter D0 × initial tube wall thickness t0 × bending radius R）, and qualified tubes are produced.展开更多
Recent new technology developments were presented in the field of industrial bending operations,including flexible stretch forming and 3D rotary stretch forming.Attempts were made to give an overview of different mech...Recent new technology developments were presented in the field of industrial bending operations,including flexible stretch forming and 3D rotary stretch forming.Attempts were made to give an overview of different mechanisms that influence dimensional accuracy,including local cross-sectional deformations such as suck-in and volume conservation effects,along with global deformations such as springback.An analytical model was developed to determine the particular influence of different material,geometry and process parameters on dimensional variability of bent components.The results were discussed in terms of overall process capability(Cp) and associated process windows.The results show that different governing mechanisms prevail in various bending operations,meaning that attention has to be placed on controlling those process parameters that really are important to part quality in each specific case.Several strategies may be defined for reducing variability.One alternative may be to design more robust process and tool technology that reduce the effect of upstream parameters on dimensional variability of the formed part.The results show that optimal tool design and technology may in specific cases improve the dimensional accuracy of a formed part.Based on the findings discussed herein,it is concluded that advances in industrial bending operations require focus on improving the understanding of mechanical mechanisms,including models and parameter development,new technology developments,including process,tool,measurement and control capabilities,and process discipline at the shop floor,combined with a basic philosophy of controlling process parameters rather than part attributes.展开更多
基金Projects (50905144, 50875216) supported by the National Natural Science Foundation of ChinaProject (09-10) supported by the State Key Laboratory of Materials Processing and Die & Mould Technology, ChinaProject (JC201028) supported by the Northwestern Polytechnical University Foundation for Fundamental Research, China
文摘Thin-walled aluminum alloy tube numerical control （NC） bending with small bending radius is a complex process with multi-factor coupling effects and multi-die constraints. A significance-based optimization method of the parameters was proposed based on the finite element （FE） simulation, and the significance analysis of the processing parameters on the forming quality in terms of the maximum wall thinning ratio and the maximum cross section distortion degree was implemented using the fractional factorial design. The optimum value of the significant parameter, the clearance between the tube and the wiper die, was obtained, and the values of the other parameters, including the friction coefficients and the clearances between the tube and the dies, the mandrel extension length and the boost velocity were estimated. The results are applied to aluminum alloy tube NC bending d50 mm×1 mm×75 mm and d70 mm×1.5 mm×105 mm （initial tube outside diameter D0 × initial tube wall thickness t0 × bending radius R）, and qualified tubes are produced.
文摘Recent new technology developments were presented in the field of industrial bending operations,including flexible stretch forming and 3D rotary stretch forming.Attempts were made to give an overview of different mechanisms that influence dimensional accuracy,including local cross-sectional deformations such as suck-in and volume conservation effects,along with global deformations such as springback.An analytical model was developed to determine the particular influence of different material,geometry and process parameters on dimensional variability of bent components.The results were discussed in terms of overall process capability(Cp) and associated process windows.The results show that different governing mechanisms prevail in various bending operations,meaning that attention has to be placed on controlling those process parameters that really are important to part quality in each specific case.Several strategies may be defined for reducing variability.One alternative may be to design more robust process and tool technology that reduce the effect of upstream parameters on dimensional variability of the formed part.The results show that optimal tool design and technology may in specific cases improve the dimensional accuracy of a formed part.Based on the findings discussed herein,it is concluded that advances in industrial bending operations require focus on improving the understanding of mechanical mechanisms,including models and parameter development,new technology developments,including process,tool,measurement and control capabilities,and process discipline at the shop floor,combined with a basic philosophy of controlling process parameters rather than part attributes.
