Investigation of new tool design for incremental profile forming
Investigation of new tool design for incremental profile forming
复制标题
渐进型材成形新模具设计研究
DOI：
10.1016/j.proeng.2017.10.936
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发表时间：
2017
期刊：
影响因子：
--
通讯作者：
Ben Khalifa
中科院分区：
文献类型：
--
作者：
Grzancic;Hiegemann;Ben Khalifa
渐进式轮廓成形（IPF）是一种高度灵活和通用的工艺，用于制造沿管中心线沿着具有可变截面设计的管状零件。在增量方法中，具有任意几何形状的多个成形工具进入管中并沿沿着预定义的工具路径移动以使期望的管形状变形。由于使用刚性成形工具，工具和工件之间存在滑动摩擦接触，导致若干工艺限制。一方面，由于工具和工件之间的接触区域附近的高拉伸应力，在成形区中发生撕裂。另一方面，由于磨损，工件在表面质量方面的性能降低。与工件表面区域处于两次接触载荷下的增量板成形工艺不同（假设后续刀具路径之间的侧重叠为50%），IPF中的变形表面区域经历几次重复接触载荷，导致相对较高的磨损发生率。为了改善表面质量以及通过减少摩擦来降低近接触区域的载荷，引入了IPF的新型工具设计，该设计允许材料流更平滑地过渡到成形区域。除了刚性工具外，还设计了一种基于滚子的工具，以滚动摩擦模式取代传统的滑动摩擦。在实验研究中，工具形状以及滚动摩擦条件的影响进行了检查。比较分析表明，工艺力减少了使用新的工具设计，导致更高的成形性在IPF，因为更高的径向工具进给是可以实现的。为了分析工件和成形工具之间的接触区域中的分量载荷（例如接触应力和相应的分布），开发了数值模型。可以证明在接触附近区域中的工艺限制拉伸应力的显著降低。除了减少加工力外，通过使用新的刀具设计，还实现了表面质量的改善以及工件几何形状的更精确。
Incremental Profile Forming (IPF) is a highly flexible and versatile process for the manufacture of tubular parts with variable cross-section design along the centre-line of the tube. Within an incremental approach multiple forming tools with arbitrary geometries indent into the tube and move along predefined tool paths to deform the desired tubular shape. Since rigid forming tools are used, a sliding friction contact between tool and workpiece exists leading to several process limits. On the one hand tearing occurs in the forming zone due to high tensile stresses near the contact area between tool and workpiece. On the other hand the workpiece properties in terms of surface quality decrease due to wear. Unlike incremental sheet forming processes, where the workpiece surface area is under contact load twice (assuming a 50 % side overlap between subsequent tool paths), the deformed surface areas in IPF experience several repetitive contact loads leading to comparatively higher occurrence of wear. In order to improve surface qualities as well as to lower the loads in near contact regions by the reduction of friction, novel tool designs for IPF are introduced which allow a smoother transition of the material flow into the forming region. Besides a rigid tool, a roller-based tool is designed for substituting the conventional sliding friction by a rolling friction mode. Within experimental studies the influence of the tool shape as well as the rolling friction condition was examined. Comparative analyses show that the process forces are decreased by the use of the new tool designs leading to higher formability in IPF since a higher radial tool infeed is achievable. For the analysis of the component loads e.g. contact stresses and corresponding distributions in the contact region between workpiece and forming tool a numerical model is developed. A significant reduction of process limiting tensile stresses in contact near regions could be proven. Beside the reduction of process forces an improvement of the surface quality as well as a more accurate geometry of the workpiece were achieved by the use of the new tool designs.
DOI：
10.1115/1.4033521
发表时间：
2016
影响因子：
4
作者：
Grzancic;Becker;Ben Khalifa
通讯作者：
Ben Khalifa
用于增量型材成型的创新机器设计
DOI：
10.4028/www.scientific.net/kem.622-623.413
发表时间：
2014
期刊：
Key Engineering Materials
影响因子：
--
作者：
Goran Gržančić;C. Becker;M. Hermes;A. Tekkaya
通讯作者：
A. Tekkaya