Bulge is a defect that causes geometrical inaccuracy and premature failure in the innovative incremental sheet forming (ISF) process. This study has two-fold objectives:(1) knowing the bulging behavior of a Cu clad tr...Bulge is a defect that causes geometrical inaccuracy and premature failure in the innovative incremental sheet forming (ISF) process. This study has two-fold objectives:(1) knowing the bulging behavior of a Cu clad tri-layered steel sheet as a function of forming conditions, and (2) analyzing the bending effect on bulging in an attempt to identify the associated mechanism. A series of ISF tests and bending analysis are performed to realize these objectives. From the cause-effect analysis, it is found that bulge formation in the layered sheet is sensitive to forming conditions in a way that bulging can be minimized utilizing annealed material and performing ISF with larger tool diameter and step size. The bending under tension analysis reveals that the formation of bulge is an outgrowth of bending moment that the forming tool applies on the sheet during ISF. Furthermore, the magnitude of bending moment depending upon the forming conditions varies from 0.046 to 10.24 N·m/m and causes a corresponding change in the mean bulge height from 0.07 to 0.91 mm. The bending moment governs bulging in layered sheet through a linear law. These findings lead to a conclusion that the bulge defect can be overcome by controlling the bending moment and the formula proposed can be helpful in this regards.展开更多
For contact dominated numerical control(NC) bending process of tube, the effect of friction on bending deformation behaviors should be focused on to achieve precision bending forming. A three dimensional(3D) elastic-p...For contact dominated numerical control(NC) bending process of tube, the effect of friction on bending deformation behaviors should be focused on to achieve precision bending forming. A three dimensional(3D) elastic-plastic finite element(FE) model of NC bending process was established under ABAQUS/Explicit platform, and its reliability was validated by the experiment. Then, numerical study on bending deformation behaviors under different frictions between tube and various dies was explored from multiple aspects such as wrinkling, wall thickness change and cross section deformation. The results show that the large friction of wiper die-tube reduces the wrinkling wave ratio η and cross section deformation degree ΔD and increases the wall thinning degree Δt. The large friction of mandrel-tube causes large η, Δt and ΔD, and the onset of wrinkling near clamp die. The large friction of pressure die-tube reduces Δt and ΔD, and the friction on this interface has little effect on η. The large friction of bending die-tube reduces η and ΔD, and the friction on this interface has little effect on Δt. The reasonable friction coefficients on wiper die-tube, mandrel-tube, pressure die-tube and bending die-tube of 21-6-9(0Cr21Ni6Mn9N) stainless steel tube in NC bending are 0.05-0.15, 0.05-0.15, 0.25-0.35 and 0.25-0.35, respectively. The results can provide a guideline for applying the friction conditions to establish the robust bending environment for stable and precise bending deformation of tube bending.展开更多
A roll-bending process that minimizes the flat areas on the leading and trailing ends of formed plates will produce more accurate and easier assemble final shapes. There are several methods of minimizing flat areas, b...A roll-bending process that minimizes the flat areas on the leading and trailing ends of formed plates will produce more accurate and easier assemble final shapes. There are several methods of minimizing flat areas, but they are costly or difficult to apply for thick plates. This study proposes a new, simple approach that reduces these flat areas. This approach includes moving the bottom roll slightly along the feeding direction and adjusting the bottom roll location. Sensitivity analyses were performed using a developed 3D dynamic FE （finite element） model of an asymmetrical roll-bending process in the Ansys/LS-Dyna software package. Simulations were validated by experiments run on an instrumented roll-bending machine. The FE results indicate that this new approach not only minimizes the flat areas but also reduces the forming forces.展开更多
基金the financial help and technical support that King Abdulaziz University provided for this research work
文摘Bulge is a defect that causes geometrical inaccuracy and premature failure in the innovative incremental sheet forming (ISF) process. This study has two-fold objectives:(1) knowing the bulging behavior of a Cu clad tri-layered steel sheet as a function of forming conditions, and (2) analyzing the bending effect on bulging in an attempt to identify the associated mechanism. A series of ISF tests and bending analysis are performed to realize these objectives. From the cause-effect analysis, it is found that bulge formation in the layered sheet is sensitive to forming conditions in a way that bulging can be minimized utilizing annealed material and performing ISF with larger tool diameter and step size. The bending under tension analysis reveals that the formation of bulge is an outgrowth of bending moment that the forming tool applies on the sheet during ISF. Furthermore, the magnitude of bending moment depending upon the forming conditions varies from 0.046 to 10.24 N·m/m and causes a corresponding change in the mean bulge height from 0.07 to 0.91 mm. The bending moment governs bulging in layered sheet through a linear law. These findings lead to a conclusion that the bulge defect can be overcome by controlling the bending moment and the formula proposed can be helpful in this regards.
基金Project(51164030)supported by the National Natural Science Foundation of China
文摘For contact dominated numerical control(NC) bending process of tube, the effect of friction on bending deformation behaviors should be focused on to achieve precision bending forming. A three dimensional(3D) elastic-plastic finite element(FE) model of NC bending process was established under ABAQUS/Explicit platform, and its reliability was validated by the experiment. Then, numerical study on bending deformation behaviors under different frictions between tube and various dies was explored from multiple aspects such as wrinkling, wall thickness change and cross section deformation. The results show that the large friction of wiper die-tube reduces the wrinkling wave ratio η and cross section deformation degree ΔD and increases the wall thinning degree Δt. The large friction of mandrel-tube causes large η, Δt and ΔD, and the onset of wrinkling near clamp die. The large friction of pressure die-tube reduces Δt and ΔD, and the friction on this interface has little effect on η. The large friction of bending die-tube reduces η and ΔD, and the friction on this interface has little effect on Δt. The reasonable friction coefficients on wiper die-tube, mandrel-tube, pressure die-tube and bending die-tube of 21-6-9(0Cr21Ni6Mn9N) stainless steel tube in NC bending are 0.05-0.15, 0.05-0.15, 0.25-0.35 and 0.25-0.35, respectively. The results can provide a guideline for applying the friction conditions to establish the robust bending environment for stable and precise bending deformation of tube bending.
文摘A roll-bending process that minimizes the flat areas on the leading and trailing ends of formed plates will produce more accurate and easier assemble final shapes. There are several methods of minimizing flat areas, but they are costly or difficult to apply for thick plates. This study proposes a new, simple approach that reduces these flat areas. This approach includes moving the bottom roll slightly along the feeding direction and adjusting the bottom roll location. Sensitivity analyses were performed using a developed 3D dynamic FE （finite element） model of an asymmetrical roll-bending process in the Ansys/LS-Dyna software package. Simulations were validated by experiments run on an instrumented roll-bending machine. The FE results indicate that this new approach not only minimizes the flat areas but also reduces the forming forces.
