A multipass incremental sheet forming strategy of a car taillight bracket
A multipass incremental sheet forming strategy of a car taillight bracket
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DOI：
10.1007/s00170-013-5179-3
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发表时间：
2013-07
期刊：
影响因子：
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通讯作者：
L. Junchao;Shen Junjian;Wang Bin
中科院分区：
文献类型：
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作者：
L. Junchao;Shen Junjian;Wang Bin
渐进板料成形(ISF)满足了日益增长的小批量产品或定制零件的生产需求。然而，到目前为止，由于加工时间长，难以生成合适的刀具轨迹，对几何复杂产品的ISF加工工艺的研究或应用还很少。本文对具有复杂几何特征的汽车尾灯支架进行了加工，特别是近直壁区和凹槽区的加工。首次验证了采用传统的多道次成形时，容易在目标产品的两个关键区域产生裂纹和皱纹。在此基础上，提出了一种基于细部区域划分并考虑加工深度的多通道策略。该策略只需要一种过渡模型，从而缩短了制造周期。以这种方式，与每个区域相关联的是对应的刀具路径，该刀具路径可以容易地修改。基于所提出的多道次设计，成功地加工了尾灯支架，没有明显的成形缺陷。厚度减薄率基本满足25%以下的常规要求。然后，由于过渡模型对最终产品的成形性能起着重要作用，因此对上述两个关键区域的补充面的设计进行了讨论。验证了几何上更接近最终形状的规则过渡曲面能够获得满意的成形质量。
Incremental sheet forming (ISF) satisfies the increasing demand for the production of small batch products or customized parts. Up to now, however, there are little studies or applications on the ISF process of geometrically complex products as a result of the long processing time and the difficulty in generating an appropriate tool path. In this study, an attempt was made to process a car taillight bracket which had several intricate geometrical characteristics, especially the nearly straight-wall region and the groove region. It was firstly verified that cracks and wrinkles are prone to be brought about in the two crucial regions of the target product if a traditional multipass forming was employed. Thus, a multipass strategy, based on a detailed area division which considered the processing depth, was approached. And this strategy required only one transitional model so as to shorten the manufacturing cycle. In this way, associated with each region was a corresponding tool path which can be easily modified. Based on the proposed multipass design, the taillight bracket was successfully processed without evident forming defects. And the thickness thinning rate approximately met the conventional requirement of less than 25 %. Then, as the transitional model plays an important role in the forming performance of the final product, the design of the addendum surface of the aforementioned two critical areas was discussed. It was verified that a regular transitional surface which is geometrically nearer to the final shape is able to obtain a satisfying forming quality.