Process Sequence Design in Metal Forming

该项目是先前金属成型工艺设计项目的延续。 制造研究的一个目标是完成适当的设计和控制过程，以最经济地生产所需零件。 金属成型工艺设计最重要的方面之一是预成型件和工艺顺序的设计。在之前的项目中，研究了复杂成型工艺中预成型件设计新方法的应用。 该方法利用有限元方法对成形过程进行正向模拟和反向跟踪的能力。 重大成就是有限元方法的开发和三维变形过程的向后追踪程序的实现。 这些研究的结果表明，无需借助设计师的经验即可设计预成型件。 在之前的项目中，考虑的设计标准是最终产品的几何要求。 对于工艺顺序设计，必须在设计过程中引入附加要求。 因此，研究的目的是开发系统工艺序列设计的方法，除了几何要求之外，还考虑材料成形性、无缺陷金属流动和经济模具制造的定量要求。 许多工业零件是由多个模具依次成型的，每个模具都会导致最终形状的变化。 该项目将提供用于设计所需模具的分析工具，这些模具现在是根据经验通过反复试验来设计的。

This project is a continuation of the prior project on Process Design in Metal Forming. A goal of research in manufacturing is to accomplish proper design and control of processes for producing required parts most economically. One of the most important aspects of process design in metal forming is design of preforms and process sequence. In the prior project, the application of the new approach to preform design in complex forming processes has been investigated. The approach used capability of forward simulation and backward tracing of a forming process by the finite element method. Significant accomplishments were the development of the finite element method and implementation of the backward tracing procedure for three dimensional deformation processes. The results of these investigations demonstrate that it is possible to design preforms without resort to designer's experience. In the prior project, the design criterion considered was a geometrical requirement for the final product. For process sequence design, additional requirements must be introduced in the design process. Thus, the objective of the research is to develop the methodology for systematic process sequence design, considering quantitatively requirements for material formability, defects-free metal flow and economic die manufacturing, in addition to the geometrical requirement. Many industrial parts are formed sequentially by multiple dies, each of which contributes to the final shape change. The project will provide analytical tools for designing the required dies, which are now designed by trial and error, based on experience.