Kinematic Tool-Bound Profile Bending using Transformer-Tools

该项目的总体目标是通过对刀具工作表面的原位调整，将刀具束缚型型材弯曲过程的灵活性提高到部分运动学过程，这是由主动的、可变的桁架状晶格结构产生的。除了传感器、执行器和控制系统的必要发展外，有关工具设计的机械问题也将首先进行研究。这些重点是所提议项目的核心，其中两位提议者正在研究互补的主题。本文首先研究了刀具工作表面的几何设计方法，主要考虑了刀具工作表面的尺寸和几何形状，以及工件之间的间隙和肩的排列。为此，将在项目范围内研究分段对局部变形行为的影响，以及基于局部作用的法向和弯曲应力的封闭型材的最终整体变形行为。每个刀具段都被理解为一个潜在的执行器，不仅允许对表面轮廓进行重大改变，还允许对刀具边界和部分运动学设计进行局部调整。因此，进一步的目标是研究修改成形工具表面的机制，作为原位调整的基础。在分析传统封闭刀面旋转拉伸弯曲过程中的局部作用应力的基础上，推导出了一种分段刀面弯曲形状的生成方法，该方法可以产生局部可变和时变的弯曲半径。因此，作为第二项研究目标的工具结构必须能够诱导这些随时间和位置变化的分段位移，并同时从成形过程中获得载荷。为了实现这一总体目标，人们正在探索新的形状和拓扑优化方法，以模拟如何使用混合整数优化（MIP）找到这样的杆结构工具设计。该方法的核心是从大量的可能性中提取基于模型的解决方案，这导致了工程实践中的功能工具，但在模型中是接近最优的。结合两位提议者开发的方法，将结果汇集到联合工作包中。目的是开发一种弯曲工具的设计方法，该方法将成形相关的边界条件与确定桁架晶格结构的算法相结合。最后，这些结果将导致变压器工具的功能模型，这将被用来验证开发的设计方法，并显示可能的技术概念。

The overall objective of this project is to increase the flexibility of tool-bound profile bending processes to partially kinematic processes trough in-situ adjustment of tool working surfaces, which are generated by active, variable truss-like lattice structures. In addition to the necessary development of sensors, actuators and control systems, mechanistic issues regarding the tool design are to be investigated first. These focus the core of the proposed project, in which the two proposers are working on complementary topics. The first proposer deals with the tool working surfaces aiming for researching methods for the geometric design of segmented surfaces with respect to size and geometry alongside to the arrangement of gaps and shoulders between the segments. For this purpose, the effect of the segmentation on the local deformation behaviour as well as the resulting global deformation behaviour of closed profiles based on the locally acting normal and bending stress, will be investigated in the scope of the project. Each tool segment is understood as a potential actuator, not only allowing a major change of the surface contour, but also the local adjustment of tool-bound and partially kinematic design. Therefore, a further aim is to investigate mechanisms for modifying the shaping tool surfaces as a basis for in-situ adjustment. Based on an analysis of the local acting stresses during rotary draw bending with conventionally closed tool surfaces, finally a method for the generation of bending shapes with segmented tool surfaces is derived, with which a locally and temporally variable bending radius can be produced.The tool structure, which is the research aim of the second proposer, must consequently be able to induce these time- and location-variable segment displacements and simultaneously derive the loads from the forming process. With this overarching goal, new shape and topology optimization methods are being explored to model how to find such a rod structured tool design using mixed integer optimization (MIP). The core of the methodology is to extract model-based solutions from a large number of possibilities, which lead to functional tools in engineering practice, but are near-optimal within the models. Combining the methods developed by both proposers, the outcomes are brought together in the joint work packages. The aim is to develop a design method for bending tools that couples the forming-related boundary conditions with the algorithms for determining the truss-like lattice structure. Concluding, these results will lead to functional models of transformer-tools, which will been used to validate the developed design method and to show possible technical concepts.