Investigations of the springback compensation on air bending with incremental stress superposition

由于能源和原材料成本的上升，创新的轻量化技术比以往任何时候都更加重要。为了实现轻量化高强度薄壁结构，具有恒定或可变厚度的片状材料比普通材料具有许多优点。这些材料的成型是个难题。由于它们的回弹量相对较高，而且通常不知道回弹，因此会发生较大的形状和尺寸变化，因此需要随后的校准和后处理过程。空气弯曲尤其如此，由于其高灵活性，它已被广泛的工业应用。在这个项目中，通过应用“空气弯曲与增量应力叠加”的新方法，研究了技术选择，以显着减少回弹量。这种新变形的一个特点和优点是在成形区局部压应力叠加。这导致了局部回弹补偿。由于辊通过弯曲线的运动，可以实现恒定的弯曲角度。由于这种方法既不需要昂贵的工具，也不需要复杂的控制，因此它为轻质材料的成型提供了一种灵活而经济的替代方法。为了可靠地生产量身定制的、轮廓完美的弯曲部件，通过空气弯曲与增量应力叠加，需要对该过程有深刻的理解。因此，需要对应力叠加过程进行详细的了解。在此过程中，组件的可实现精度和质量都必须事先众所周知。应用和制造限制也是如此，以证明工业应用适用于高强度材料薄板和定制坯料的弯曲。因此，该项目的目标是科学地发展基础知识，并将其应用于一种新的弯曲方法。这种新颖的工艺使制造灵活和经济的创新轻质部件成为可能，这些部件由高质量的新材料制成。

Innovative lightweight technologies are more important than ever because of rising energy and raw material costs. For the implementation of lightweight high-strength thin-walled structures, sheet materials with constant or variable thickness offer numerous advantages over common materials. Forming these materials represents a high problem. Because of their comparatively high amount, and usually unknown springback, larger shape and dimensional variations occurs, so a subsequently calibration and post-processing processes are required. This is particularly true for air bending, which has found wide industrial application due to its high flexibility.In this project, technological options are examined to reduce the amount of springback significantly by applying the new method "air bending with incremental stress superposition". A particular feature and advantage of this new variant is the local compressive stress superposition in the forming zone. This results in a local springback compensation. Due the movement of the roll through the bending line, a constant bending angle can be achieved. Since this method neither requires expensive tools nor a complex control, it provides a flexible and cost effective alternative to other methods for forming of lightweight materials.For a reliable production of tailor-made and perfectly contoured bent parts by air bending with incremental stress superposition, a deep understanding of the process is required. So a detailed knowledge of the processes taking place during the stress superposition is needed. In the process both the achievable accuracy and quality of the component have to be well known in advance. The same is true for the applications and manufacturing limits in order to demonstrate the industrial application suitability for the bending of both thin sheets of high-strength materials and tailored blanks.So the objective of the project is the scientific development of fundamental knowledge and its implementation in a novel bending method. This novel process gives the possibility to manufacture flexible and economical innovative lightweight components made of new materials produced at a high level of quality.