scholarly journals Approach for the Development of Forming Tools for Radial Rotation Profile-Forming

2019 ◽  
Vol 949 ◽  
pp. 125-133
Author(s):  
Robert Laue ◽  
Sebastian Härtel ◽  
Birgit Awiszus
Keyword(s):  
Radial Profile ◽  
Sheet Thickness ◽  
Forming Process ◽  
Process Step ◽  
Forming Simulation ◽  
General Law ◽  
Incremental Sheet Metal Forming ◽  
Metal Forming Process ◽  
Axial Profile ◽  
Forming Tools

The incremental forming process Radial Rotation Profile-Forming (RRPF) has been developed to enable the production of profiled hollow parts with low sheet thinning and high geometrical accuracy. As a result of low thinning, a smaller initial sheet thickness can be used, while material and weight can be saved.The two principal forming steps are the production of the preform by Rotational Swing-Folding (RSB) and the subsequent radial profile forming of the hollow part in one clamping position. The special feature are the purposed wrinkles in the first process step, which formed in the indentation of the profiled mandrel. This is an advantage, because of the additional thickening. Due to the radial profiled forming in the second process step, the axial profile can be formed with less thinning.The focus of the article is on the development of the forming tools for the second process step of RRPF. Based on the general law of gearing, the forming tools for the production of a component are developed. First, a forming simulation of an example component validates the approach. For this purpose, some simplifications have been made in order to consider the profile forming process separately. Afterwards, the experimental results of the incremental sheet metal forming process for the production of the profiled hollow parts are presented.

A Study on Incremental Forming of Vertical Wall Square Box with Small Radius Corner

2010 ◽  
Vol 139-141 ◽  
pp. 1510-1513
Author(s):  
Liu Ru Zhou
Keyword(s):  
Tool Path ◽  
Vertical Wall ◽  
Small Radius ◽  
Forming Process ◽  
Corner Radius ◽  
Single Process ◽  
Incremental Sheet Metal Forming ◽  
Metal Forming Process ◽  
Sine Law ◽  
Square Box

According to sine law, a vertical wall square box can’t be formed by NC incremental sheet metal forming process in a single process, rather, it must be formed in multi processes. A vertical wall square box can be considered to consist of corners and straight sides. Straight sides and corners affect each other and the effect is different in various square boxes. The effect depends on the ratio r/B of the corner radius r and straight side width B. The smaller r/B, the larger the effect of straight side on corner is. In this case, the deformation in the straight sides isn’t even, and the metal of the corner is compressed and gradually piled up. With the increase of r/B, the deformation becomes more uniform. The tool path with gradually reduced corner radius is adopted to overcome this question. A vertical wall square box with small corner radius is successfully formed.

3D Loading Path-Generating Method for FEM Simulation of Incremental Sheet Metal Forming Process

2010 ◽  
Vol 97-101 ◽  
pp. 2810-2815 ◽  
Author(s):  
Yan Xu ◽  
Shuang Gao Li ◽  
Lin Gao
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Fem Simulation ◽  
Loading Path ◽  
Forming Process ◽  
Forming Simulation ◽  
Generating Method ◽  
Incremental Sheet Metal Forming ◽  
3D Loading

Incremental forming of sheet metal is difficult to be simulated for its complicated 3D loading path. In this work, an acceptable approach to generate 3D loading path, called “virtual guiding model method” is accomplished. The method, which has the similar idea with the conventional copy mill, is based on FEM and the basic principle of kinematics. With the help of the method, multi-stage incremental forming of a drawing typed square cup was simulated in the FEM software-PAMSTAMP and experimented. Through measuring the thickness distribution the vertical edge of the cup, the most difference between them is less than 0.05mm, which is satisfied with engineering request, and the results shows that the 3D loading path generating method is one of the most effective way to realize the incremental forming simulation.

The Evaluation of Ductile Fracture Criteria (DFC) of 6061-T6 Aluminum Alloy

2010 ◽  
Vol 44-47 ◽  
pp. 2837-2841 ◽  
Author(s):  
Ying Tong
Keyword(s):  
Aluminum Alloy ◽  
Ductile Fracture ◽  
Metal Forming ◽  
True Strain ◽  
Mutual Support ◽  
Fracture Criteria ◽  
Forming Process ◽  
Forming Simulation ◽  
Ductile Fracture Criteria ◽  
Metal Forming Process

As one of the principal failures, ductile fracturing restricts metal forming process. Cockcroft-Latham fracture criterion is suited for tenacity fracture in bulk metal-forming simulation. An innovative approach involving physical compression experiments, numerical simulations and mathematic computations provides mutual support to evaluate ductile damage cumulating process and ductile fracture criteria (DFC). The results show that the maximum cumulated damage decreases with strain rate rising, and the incremental ratios, that is damage sensitive rate, vary uniformly during the upsetting processes at different strain rates. The damage sensitive rate decreases rapidly, then it becomes stability in a constant 0.11 after true strain -0.85. The true strain -0.85 was assumed as the fracture strain, and the DFC of 6061-T6 aluminum alloy is almost a constant 0.2. According to DFC, the exact fracture moment and position during various forming processes will be predicted conveniently.

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