Adaptive Stretch-Forming Process: A Computer Vision and Statistical Analysis Approach

An industrial process is defined through its quality of parts and their production costs. Labour-intensive operations must be applied to produce high-quality components with inexpensive resources. Recent development in dedicated software allows the industrial sector to rely on more and more autonomous solutions to obtain an optimum ratio between part quality and cost. The stretch forming process is an operation that has a high degree of difficulty, due to the process parameters and the spring-back effect of materials. Our approach to solving several of the shortcomings of this process was to develop a self-adaptive algorithm with computer vision capabilities that adapts to the process in real-time. This experimental study highlights the results obtained using this method, as well as a comparison to a classical method for the stretch-forming process (SFP). The results have noted that the stretch-forming algorithm improves the process, while adapting its decisions with each step.

On the Parallel Kinematics of the FET Stretching Press in the Stretch Forming Operations in the Manufacture of Parts with Complex Spatial Geometry

The kinematics of a stretching press mechanism of a parallel structure are investigated. The kinematic dependences aimed at setting the spatial position of the working elements of a cross-stretching press of FET type, which allow positioning its jaws at any time during the technological operations, are obtained. The forward and inverse control kinematics problems of the jaw mechanism stretching press are solved

Strain Hardening and Stretch Formability Behavior of Triple Phase (TP) Steel Strips

The current work explores the strain hardening and stretches formability behaviour of the developed Triple Phase (TP) steel. Double quenched TP steel strips posse three distinguished stages of strain hardening on tensile forming. 1st stage represents the highest n-value reflecting resistance to homogeneous deformation, where steel can be safely stretched. 2nd and 3rd stage reveals lower n-values, where localized thinning exist. On Erichsen testing, the relationship between punch forming force and punch stroke exhibits two forming regions. The 1st region is delineated by a straight line showing an ultra-high strain-hardening rate, which represents a reversible elastic stretch forming. The 2nd forming region continues to a higher Erichsen punch stroke than that of the 1st region and presents the permanent plastic stretch forming behaviour. It is found that bainite and martensite clusters created, by double quenching, in TP-steel exaggerated the elastic stretch forming limit 10 times higher than the as-hot rolled condition. 7 min. holding time of strips in the salt bath is considered the most effective for the creation of a useful volume fraction of the bainite phase. However, 21 min. holding time in salt bath grows martensite laths through the bainite aggregates, affecting negatively on stretch formability.

Optimization of Multi-Point Forming for Aluminum Alloy Profile

According to the profile processing, two forming processes are proposed, i.e., multi-point stamping forming and multi-point stretch forming. Through the finite element simulation, two forming processes are simulated and compared. The analysis results show that the longitudinal springback and transverse forming error of parts by multi-point stretch forming are smaller than those by multi-point stamping forming, so the multi-point stretch forming process is suitable for processing this kind of aluminum alloy profile.

Stretch Forming of Ti-6Al-4V Hybrid Parts at Elevated Temperatures

Hybrid components produced by two or more different process technologies grant the possibility to compensate the drawbacks of the used processes. The combination of additive manufacturing (AM) and forming offers geometrical freedom in extensions of geometrical simple parts in a cost-efficient way. Unlike the combination of bulk metal forming and AM, sheet metal forming and AM is less investigated. Especially for Ti-6Al-4V, which is widely used in AM but has a low formability at room temperature, research is still needed. In this study, the formability of hybrid parts made of Ti‑6Al‑V consisting of sheet material and additively manufactured elements (AME) is investigated for a hemispherical punch geometry. Thus, a designed tool for forming of hybrid parts at elevated temperatures is used. First investigations with a specially designed stretch forming tool demonstrate the distinct influence of the additively manufactured bodies on the stretch forming process of hybrid parts made of Ti‑6Al‑4V. Namely, the achievable drawing depth is reduced for hybrid parts as the functional elements are placed in the area of highest stresses, distorting material flow.