Sheet Bulk Forming of Thin-Walled Components with External Gearing through Upsetting Using Controllable Deformation Zone Method

Sheet-bulk metal forming (SBMF) is a promising process for manufacturing complex sheet components with functional elements. In this study, the entire forming process for a typical thin-walled component with external gearing is investigated, including sheet forming and bulk forming processes. Deep drawn cups are prepared during sheet forming; subsequently, upsetting is performed on the sidewall to form external gearing. The upsetting method performed is known as upsetting with a controllable deformation zone (U-CDZ). Compared with the conventional upsetting method, a floating counter punch with a counter force is used in the U-CDZ method such that the forming mechanism is changed into the accumulation of the deformation zone instead of deformation throughout the entire sidewall. The effects of the counter force and material flow are investigated to understand the mechanism. The forming quality, i.e., the formfilling and effective strain distribution, improved, whereas a high forming load is avoided. In addition, a punch with a lock bead is used to prevent folding at the inner corner during the experiment.

Optimization of Controllable Deformation Zone And Die Wear of Aluminum Crown Forgings For Shock Absorber Assembly

In this research, numerical analysis, response surface method (RSM) and experiments are used to investigate and verify the hot forging process for manufacturing aluminum crown forgings for shock absorber assembly. First, establish the computer aided design (CAD) model of the die and the billet, and simulate it from the finite element method (FEM). Second, a new preforming die was designed with a preformed dressing of controllable deformation zone (CDZ) by the CAD software. Third, numerical simulation was combined with RSM to optimize the processing parameters with the aim of minimizing the die wear while the integrity of forgings should be prioritized preserved. According to RSM, the billet size and preformed dressing of CDZ are important factors affecting the distance between die and workpiece (C). The optimal design factor of the preforming die: billet diameter (D), billet length (L) and flash design (F) are 40 mm, 205 mm and CDZ 1, respectively. Through the results of FEM, this study describes the distribution of microscopic grain flow lines are highly related to forming, stress, strain, and temperature as well as die design such as CDZ in preformed dressing. In order to accurately verify that the parameters analyzed by the RSM, both numerical analysis and physical experiments are carried out and optimal scheme exhibit reasonable consistency.

Programmable and reprocessable multifunctional elastomeric sheets for soft origami robots

Tunable, soft, and multifunctional robots are contributing to developments in medical and rehabilitative robotics, human-machine interaction, and intelligent home technology. A key aspect of soft robot fabrication is the ability to use flexible and efficient schemes to enable the seamless and simultaneous integration of configurable structures. Here, we report a strategy for programming design features and functions in elastomeric surfaces. We selectively modified these elastomeric surfaces via laser scanning and then penetrated them with an active particle–infused solvent to enable controllable deformation, folding, and functionality integration. The functionality of the elastomers can be erased by a solvent retreatment and reprocessed by repeating the active particle infusion process. We established a platform technique for fabricating programmable and reprocessable elastomeric sheets by varying detailed morphology patterns and active particles. We used this technique to produce functional soft ferromagnetic origami robots with seamlessly integrated structures and various active functions, such as robots that mimic flowers with petals bent at different angles and with different curvatures, low-friction swimming robots, multimode locomotion carriers with gradient-stiffness claws for protecting and delivering objects, and frog-like robots with adaptive switchable coloration that responds to external thermal and optical stimuli.

Gradient porous PNIPAM-based hydrogel actuators with rapid response and flexibly controllable deformation

Gradient PNIPAM-based intelligent hydrogels with bidirectional bending properties can realize flexibly controllable deformation and activity as soft actuators.