Three-dimensional sheet metal continuous forming process based on flexible roll bending: Principle and experiments
Three-dimensional sheet metal continuous forming process based on flexible roll bending: Principle and experiments
复制标题
基于柔性辊弯的三维板材连续成形工艺：原理与实验
DOI：
10.1016/j.jmatprotec.2011.08.014
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发表时间：
2012-01-01
影响因子：
6.3
通讯作者：
Lan, Ying-Wu
中科院分区：
文献类型：
--
作者：
Cai, Zhong-Yi;Li, Ming-Zhe;Lan, Ying-Wu
为了有效地制造小批量生产的具有各种曲率的三维钣金零件，正在发展一种新的柔性成形技术--板材连续成形。该工艺采用一个上柔性辊和两个下柔性辊作为成形工具，并且柔性辊的形状可以在垂直方向上改变。随着柔性辊的旋转，金属板在纵向和横向上同时弯曲，并且连续成形。根据成形过程的特点，采用扫描曲面描述成形件的三维曲面，建立了连续成形件的弧长参数方程。分析了板料纵向三辊弯曲变形，推导了成形件纵向曲率方程。采用三次样条曲线表示多点控制的柔性辊轴形状，分段计算回弹后成形件的横向曲率。对典型的凹曲面和马鞍型曲面进行了成形实验，利用双目立体视觉测量系统对实验结果进行了测量和分析，实验结果表明，成形曲面与所需形状吻合良好，所提出的方程可用于连续成形工艺设计。(C)2011 Elsevier B.V.保留所有权利。
To effectively manufacture three-dimensional sheet metal parts with various curvatures produced in small batch quantities, continuous sheet metal forming, a new flexible forming technology is being developed. This process employs an upper flexible roll and two lower flexible rolls as a forming tool, and the shape of a flexible roll can be changed in vertical direction. With the rotation of flexible rolls, the sheet metal is bent in longitudinal and transverse directions simultaneously and is formed continuously. In the present study, the three-dimensional surface of formed part is described by sweep surface based on the characteristic of the forming process and the arc-length parametric equation for describing continuous forming part is developed. The three-roll bending deformation of sheet metal in longitudinal direction is analyzed and the longitudinal curvature equation of the formed part is derived. The shape of flexible roll axis controlled at a number of points is represented by the cubic spline curve and the transverse curvature of the formed part after springback is then calculated piecewise. Typically experiments for forming concave shape surface and saddle-type surface have been performed, the experiment results are measured and analyzed by a binocular stereo vision measurement system, it is demonstrated that the formed surfaces are in good agreement with the desired shapes and the presented equations are useful for the continuous forming process design. (C) 2011 Elsevier B.V. All rights reserved.