Dynamic Detection of Instability Defects in tube Rotary Draw Bending

Simonetto, Enrico; Ghiotti, Andrea; Bruschi, Stefania; Gemignani, R.

doi:10.1016/j.promfg.2017.07.064

Cited by 13 publications

(5 citation statements)

References 14 publications

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“…The sensor data can be analyzed to monitor in real time the actual bending radius in a three roll push bending operation, the springback angle in a rotary draw bending operation, and the onset of wrinkles in both processes. Alternatively, a set of sensors can be positioned on most of the elements of the bending tooling, such as the bending die, wiper die, and mandrel for the rotary draw bending, to dynamically diagnose the bending defects [ 106 ]. To achieve this, the hardware and software acquisition system, the sensor calibration procedure and the analysis procedure of both the machine and sensor data need to be developed as well.…”

Section: Discussionmentioning

confidence: 99%

Advances and Trends in Forming Curved Extrusion Profiles

Zhou

Shao

et al. 2021

Materials

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Curved profiles/sections have been widely used for manufacturing lightweight structures with high stiffness and strength due to aerodynamics, structural properties, and design reasons. Structural components fabricated using curved aluminum profiles satisfy the increasing demands for products used in many high-technology industries such as aerospace, shipbuilding, high-speed rail train, and automobile, which possess the characteristics of lightweight, high strength/stiffness relative to weight, superior aerodynamics performance, and aesthetics. In this paper, the advances and trends in forming techniques of curved extrusion profiles of metal alloys have been reviewed. The curved profile forming techniques are classified into three major categories: conventional cold bending technique, stress/moment superposed cold bending technique, and extrusion-bending integrated forming technique. Processes for innovative development in the field of forming curved profiles are identified; the extrusion-bending integrated technique which can directly form the billets into curved profiles by one single extrusion operation possesses the full potential for further innovation. Due to the nature of the research to date, much of the work referred to relates to hollow circular and rectangular tube cross-sections.

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Section: Discussionmentioning

confidence: 99%

Advances and Trends in Forming Curved Extrusion Profiles

Zhou

Shao

et al. 2021

Materials

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“…In addition to the positioning of the individual components, the alignments of the wiper die and the pressure die is of particular importance Simonetto et al [11]. Further variables influencing the process are bends of the tool and the machine, therefore the stiffness of each tool and each machine axis is important.…”

Section: Formation Of Wrinkles During Rotary Draw Bendingmentioning

confidence: 99%

Influence of the stiffness of machine axes on the formation of wrinkles during rotary draw bending

2020

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This study presents that finite element (FE) simulations of rotary draw bending are improved by taking into account the stiffnesses of the machine axes. The results show the influence of the axis stiffnesses of the bend die, the wiper die, the pressure die and the mandrel on the formation of wrinkles at the inner tube bend. For this purpose the axis stiffnesses are varied in FE-simulations and wrinkle evaluation factors of the final components are determined and compared. Low axis stiffnesses correspond to large axial displacements when force is applied and cause greater wrinkle formation. In addition, practical tests are carried out on the machine to measure the axis displacements and associated forces. The resulting axis stiffnesses are entered into the FE simulation. The final geometry of the bending component of the FE simulation is compared with the geometry of a component produced in a practical test. The consideration of the axis stiffness in the calculation in contrast to ideally stiff axes provides wrinkle heights that are closer to the wrinkle heights in the practical test. The knowledge gained improves the prediction of the component quality and allows the evaluation of axis displacements measured on bending machines. The overall aim of the project is to react to machine-specific axis stiffnesses in the form of process control.

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“…3 Similar approaches applied to other processes such as tube rotary draw bending and wire drawing have shown that defects can be avoided by using optimum conditions of process variables. 4,5 JingDong et al 6 have highlighted the need to focus on improving part quality by determining FIGURE 2 Deformation of bottom panel of a can subjected to a buckle pressure test optimum process parameters using an alternative to the time-consuming "trial-and-error" procedure. However, this can be very complex, since part quality is also influenced by geometry, material, surface roughness, lubrication, and machine features.…”

Section: Figure 1 Metal Can Showing Expansion Ringsmentioning

confidence: 99%

“…Parameter optimisation is of major importance in Can manufacturing, given the variety of methods having been used to improve sheet forming processes by controlling design variables . Similar approaches applied to other processes such as tube rotary draw bending and wire drawing have shown that defects can be avoided by using optimum conditions of process variables . JingDong et al have highlighted the need to focus on improving part quality by determining optimum process parameters using an alternative to the time‐consuming “trial‐and‐error” procedure.…”

Section: Introductionmentioning

confidence: 99%

Process parameter optimisation of a minster draw‐redraw system

Seechurn

Ramlugun

2019

Engineering Reports

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Non‐conformance in Unit Depth Value (UDV) of expansion rings for metal cans makes them prone to major defects, such as swells and distortions, during the Drawing/Redrawing industrial process. In this paper, with the aim of improving the manufacturing process quality, the process parameters for the Minster Draw/Redraw machine at a generic company are optimised so as to obtain the desired UDV. The Taguchi method is used to determine the most influential process parameters. Nine experiments have been performed with four selected parameters, namely, Upper Blank Holder Pressure, Lower Blank Holder Pressure, Profile Pad Pressure, and Inner Ram Value. A multiple‐linear regression analysis is also conducted to demonstrate the relationship between UDV and the considered parameters. The best settings for the respective process parameters are obtained via Analysis of Means (ANOM). Furthermore, Analysis of Variance (ANOVA) shows that the Inner Ram Value is the process parameter that most significantly affects the formation of expansion rings. The same methodology proposed in this study can easily be extended to find the optimum settings of process parameters for different can heights. Finally, an equation is formulated to predict the setting values of the most significant process parameters under user‐specified UDVs.

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Dynamic Detection of Instability Defects in tube Rotary Draw Bending

Cited by 13 publications

References 14 publications

Advances and Trends in Forming Curved Extrusion Profiles

Advances and Trends in Forming Curved Extrusion Profiles

Influence of the stiffness of machine axes on the formation of wrinkles during rotary draw bending

Process parameter optimisation of a minster draw‐redraw system

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