Analytical prediction of wall thickness reduction and forming forces during the radial indentation process in Incremental Profile Forming
Analytical prediction of wall thickness reduction and forming forces during the radial indentation process in Incremental Profile Forming
复制标题
增量轮廓成形径向压痕过程中壁厚减少和成形力的分析预测
DOI：
10.1016/j.jmatprotec.2018.12.003
复制
发表时间：
2018
影响因子：
6.3
通讯作者：
Tekkaya
中科院分区：
文献类型：
--
作者：
Grzancic;Löbbe;Ben Khalifa;Tekkaya
增量成形（IPF）是最近引入的柔性管成形技术，其允许制造具有沿零件的纵向轴线沿着变化的横截面几何形状的管状结构。该工艺的特点主要是操作几个工具，横向移动，压痕和变形的初始管状工件。在动态IPF中，使用具有半球形刀具形状的通用刀具允许灵活制造高度复杂的零件，因为其几何形状主要由刀具运动限定。工具接触区域中的管材料变薄对于动态IPF成形过程来说是典型的。为了预测成形行为，分析模型的开发考虑管尺寸，工具的几何形状以及管材料。基于预测的成形行为，压痕过程中的过程力也被确定解析。分析模型的验证进行了实验和数值研究。在对工具接触区和管材变形进行几何分析后，描述了成形区的塑性应变分布，以预测壁厚的减小。此外，该分析模型允许预测的成形力过程中的压痕深度为各种工艺参数。
Incremental Profile Forming (IPF) is a recently introduced flexible tube forming technology, which allows the manufacture of tubular structures with varying cross-sectional geometries along the longitudinal axis of the part. The process is characterized mainly by the operation of several tools, laterally moving, indenting and deforming the initial tubular workpiece. In kinematic IPF the use of universal tools with hemispheric tool shapes allow the flexible manufacture of highly complex parts since its geometry is mainly defined by the tool motions. Thinning of the tube material in the tool contact region is typical for kinematic IPF forming processes. In order to predict the forming behavior, an analytical model is developed taking the tube dimensions, the tool geometry as well as the tube material into account. Based on the predicted forming behavior, the process force during the indentation process is also determined analytically. The validation of the analytical model is performed by experimental and numerical investigations. After the geometrical analysis of the tool contact region and the tube deformations, the plastic strain distribution in the forming zone is described, in order to predict the reduction of the wall thickness. Furthermore, the analytical model allows the prediction of the forming force course over the indenting depth for various process parameters.
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