Erweiterung von Grenzen der Stegblechumformung*/Extension of limits of stringer sheet forming

2017 ◽  
Vol 107 (10) ◽  
pp. 689-694
Author(s):  
P. Prof. Groche ◽  
S. Köhler ◽  
H. Husmann ◽  
C. Kurpiers
Keyword(s):  
Sheet Metal ◽  
Process Chain ◽  
Base Plane ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flat Sheet ◽  
Heat Treated ◽  
New Process ◽  
Stiffening Ribs

Stegbleche sind flächige Bauteile, die senkrecht zur Grundblechebene Versteifungsrippen aufweisen. Die Herstellung von räumlich gekrümmten Stegblechen findet durch Blechverzweigung im ebenen Zustand und anschließender Umformung in die Zielgeometrie statt. Beim Umformprozess ergeben sich neue Prozessgrenzen wie Risse oder Beulen an den Stegen. Dieser Fachbeitrag zeigt, wie wärmebehandelte, höhenveränderliche, vorgespannte oder im Prozess unterstützte Stege diese Grenzen um bis zu 200 % erweitern.   Stringer sheets are flat sheet metal parts, which have stiffening ribs vertical to the base plane. The production of spatially curved stringer sheets takes place in a process chain of sheet metal bifurcation in the flat state and a subsequent forming process. During this forming process, new process limits such as cracks and wrinkling occur due to the stringers. This article presents how heat-treated, height-adjusted, pre-stressed or supported stringers exceed these limits by up to 200 %.

Methodology to Produce Locally Heat-Treated EN AW-5182 Aluminum Alloy Sheet Metal Parts

2012 ◽  
Vol 504-506 ◽  
pp. 113-118 ◽  
Author(s):  
Andreas Magnus Sulzberger ◽  
Marion Merklein ◽  
Wolfgang Staufner ◽  
Daniel Wortberg
Keyword(s):  
Sheet Metal ◽  
Material Flow ◽  
Sheet Thickness ◽  
Alloy Sheet ◽  
Second Step ◽  
Material Failure ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Material Recovery ◽  
Heat Treated

Compared to steel, aluminum has a reduced formability. The consequence is that the drawability of aluminum needs to be extended. This can be achieved by a material recovery that takes place near the zones in which a material failure is initiated during deep drawing. In the considered process, first the aluminum component will be preformed to a specific stress state. In the second step, it will be partial heat treated, before the component is getting finished. Based on the selective intermediate introduction of heat, the material flow of the pre-drawn part is influenced in such a manner that the most highly stressed zones are subjected to further reduction in sheet thickness. This is possible by sacrificing material out of zones near the crack. These areas are referred to below as “sacrificial zones”. They depend on the position of the critical region as a result of the material pre-strain. In these regions, the temperature can be varied. This paper focuses on the development of a methodology to determine a layout of intermediate heat treatment of preformed aluminum sheet metal components. In order to determine such a layout, a principal part must be designed on which the methodology can be reviewed.

Forming Stability Analysis of Surface Flexible Rolling

2013 ◽  
Vol 798-799 ◽  
pp. 267-271
Author(s):  
Ren Jun Li ◽  
Ming Zhe Li ◽  
Zhong Yi Cai
Keyword(s):  
Numerical Simulation ◽  
Stability Analysis ◽  
Sheet Metal ◽  
Three Dimensional ◽  
Continuous Manufacturing ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flexible Rolling ◽  
Simulation Results

Surface flexible rolling method, using two integral working rolls as the forming tool, can achieve fast, flexible and continuous manufacturing of three-dimensional sheet metal parts. This paper introduces the basic principle of surface flexible rolling and discusses the numerical simulation results when the working rolls are bended as circular arcs. The stability indicates the forming effect to some extent and the flow type of the metal can be deduced from stability analysis. To integrate and analyze the simulation results by means of reverse engineering. The analysis results show that the forming process is stable and the effect of surface flexible rolling is fine. It also indicates that inhomogeneous deformation and accumulation occurs during the process. The numerical simulation and experimental results demonstrate that the surface flexible rolling is a feasible and effective way to form three-dimensional sheet metal parts.

scholarly journals TENDENCIES IN FORMING SHEET METAL PARTS USING INCREMENTAL FORMING ADVANCED TECHNOLOGIES

2019 ◽  
Vol 25 (3) ◽  
Author(s):  
CATALINA CIOFU ◽  
BOGDAN CHIRITA ◽  
ROXANA LUPU ◽  
COSMIN GRIGORAS ◽  
CRINA RADU ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Stretch Forming ◽  
Micro Forming ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Advanced Technologies ◽  
Metal Materials ◽  
Forming Methods

Stretch forming of sheet metal materials is a highly required process in aerospace industry for manufacturing skin parts. Automation of some processes such as cutting, punching, forming, shearing and nesting in conventional manufacturing tends to combine these forming methods. Some researches are made on the formability of sheet metal materials obtained in incremental forming process with stretch forming and water jet incremental micro-forming with supporting dies. This paper is an attempt to review the newly researches made on optimization of manufacturing metal skin parts to achieve geometrical accuracy.

scholarly journals 3D printed prototyping tools for flexible sheet metal drawing

2021 ◽  
Author(s):  
Peter Frohn-Sörensen ◽  
Michael Geueke ◽  
Tadele Belay Tuli ◽  
Christopher Kuhnhen ◽  
Martin Manns ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Processing Parameters ◽  
Polymer Materials ◽  
Compression Tests ◽  
Forming Process ◽  
Resource Saving ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Small Series ◽  
Rubber Pad Forming

AbstractDue to the change from mass production to mass personalized production and the resulting intrinsic product flexibility, the automotive industry, among others, is looking for cost-efficient and resource-saving production methods to combining global just-in-time production. In addition to geometric manufacturing flexibility, additive manufacturing offers a resource-saving application for rapid prototyping and small series in predevelopment. In this study, the FDM process is utilized to manufacture the tooling to draw a small series of sheet metal parts in combination with the rubber pad forming process. Therefore, a variety of common AM polymer materials (PETG, PLA, and ABS) is compared in compression tests, from which PLA is selected to be applied as sheet metal forming die. For the rubber pad forming process, relevant processing parameters, i.e., press force and rubber cushion hardness, are studied with respect to forming depth. The product batch is examined by optical evaluation using a metrological system. The scans of the tool and sheet metal parts confirm the mechanical integrity of the additively manufactured die from polymer and thus the suitability of this approach for small series in sheet metal drawing processes, e.g., for automotive applications.

scholarly journals TENDENCIES IN FORMING SHEET METAL PARTS USING INCREMENTAL FORMING ADVANCED TECHNOLOGIES

2019 ◽  
Vol 25 (3) ◽  
pp. 15-21
Author(s):  
CATALINA CIOFU ◽  
BOGDAN CHIRITA ◽  
ROXANA LUPU ◽  
COSMIN GRIGORAS ◽  
CRINA RADU ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Stretch Forming ◽  
Micro Forming ◽  
Forming Process ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Advanced Technologies ◽  
Metal Materials ◽  
Forming Methods

Stretch forming of sheet metal materials is a highly required process in aerospace industry for manufacturing skin parts. Automation of some processes such as cutting, punching, forming, shearing and nesting in conventional manufacturing tends to combine these forming methods. Some researches are made on the formability of sheet metal materials obtained in incremental forming process with stretch forming and water jet incremental micro-forming with supporting dies. This paper is an attempt to review the newly researches made on optimization of manufacturing metal skin parts to achieve geometrical accuracy.

scholarly journals 3D printed prototyping tools for flexible sheet metal drawing

2020 ◽  
Author(s):  
Peter Frohn-Sörensen ◽  
Michael Geueke ◽  
Tadele Belay Tuli ◽  
Christopher Kuhnhen ◽  
Martin Manns ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Processing Parameters ◽  
Polymer Materials ◽  
Compression Tests ◽  
Forming Process ◽  
Resource Saving ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Small Series ◽  
Rubber Pad Forming

Due to the change from mass production to mass personalized production and the resulting intrinsic product flexibility, the automotive industry, among others, is looking for cost-efficient and resource-saving production methods to combining global just-in-time production. In addition to geometric manufacturing flexibility, additive manufacturing offers a resource-saving application for rapid prototyping and small series in pre-development. In this study, the FDM process was utilized to manufacture the tooling to draw a small series of sheet metal parts in combination with the rubber pad forming process. Therefore, a variety of common AM polymer materials (PETG, PLA and ABS) is compared in compression tests, from which PLA is selected to be applied as sheet metal forming die. For the rubber pad forming process, relevant processing parameters, i.e. press force and rubber cushion hardness, are studied with respect to forming depth. The product batch was examined by an optical evaluation using a metrological system. The scans of the tool and sheet metal parts confirm the mechanical integrity of the additively manufactured die from polymer and thus the suitability of this approach for small series in sheet metal drawing processes, e.g. for automotive applications.

scholarly journals Vibroacoustic Optimization of Stiffening Ribs and Damping Material Distribution on Sheet Metal Parts

2004 ◽  
Vol 11 (3-4) ◽  
pp. 271-280 ◽  
Author(s):  
M. Carfagni ◽  
P. Citti ◽  
L. Governi ◽  
M. Pierini
Keyword(s):  
Sheet Metal ◽  
Dynamic Stiffness ◽  
Efficient Design ◽  
Vehicle Noise ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Novel Approach ◽  
Damping Material ◽  
Basic Parameters ◽  
Stiffening Ribs

Vehicle noise and vibration levels are basic parameters in passenger comfort. Both static and dynamic stiffness of sheet metal parts is commonly increased by means of stiffening ribs. Vibrations are also reduced by adding a layer of damping material on the floor, the roof, the firewall and other parts of the vehicle. In common practice the panels to be treated are ribbed according to criteria based on the designer’s experience, rather than on well defined design procedures and are uniformly covered by a layer of damping material. However, these are not efficient design solutions, especially with regard to the effectiveness of vibration reduction and to weight containment. In this paper a novel approach to achieve an optimal distribution of stiffening ribs and damping material will be presented. The proposed method is based on a Genetic Algorithm (G.A.) procedure which takes into account both the vibroacoustic performance and the weight and cost reduction. A simple case study will be illustrated to demonstrate the capabilities of the developed procedure.

Robot-Forming - An Incremental Forming Process Using an Industrial Robot by Means of DELMIA Software Package

2013 ◽  
Vol 371 ◽  
pp. 416-420 ◽  
Author(s):  
Ionut Chera ◽  
Octavian Bologa ◽  
Sever Gabriel Racz ◽  
Radu Eugen Breaz
Keyword(s):  
Sheet Metal ◽  
Software Package ◽  
Incremental Forming ◽  
Industrial Robot ◽  
Metal Part ◽  
Forming Process ◽  
Program Code ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Custom Made

The purpose of this research is to present an alternative method for manufacturing sheet metal parts using an asymmetric incremental forming process by means of an industrial robot. This method is based on designing, simulating and generating the toolpath for the tool attached to the robot using DELMIA software package. The proposed approach allows users to check for system collisions, robot joins limitations and singularity problems. After a comprehensive simulation of the movements of the robot is performed, the program code can be generated by means of a specific DELMIA function. The program can be used afterwards to control the robot during the experimental work. In order to demonstrate the capabilities of robot-forming, a truncated pyramid sheet metal part was manufactured using a custom made stand and with the help of a KUKA KR6 anthropomorphic robot.

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