Study on multiple-step incremental air-bending forming of sheet metal with springback model and FEM simulation

Fu, Zemin; Mo, Jinhan; Zhang, Wenxian

doi:10.1007/s00170-009-1982-2

Cited by 19 publications

(8 citation statements)

References 13 publications

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“…The angles between line E and the tangent lines of hi km are regarded as springback angle in each step bending after unloading; for instance, the angle 2 is the springback angle in the second step bending after unloading. The offset between the two concentric semi-ellipses R + t/2 is 201.5 mm, where R is solved with the simplified mathematical model formula R = t t r −3 03 E developed by Fu et al [15]. Likewise, according to experiment 1 demand in Table 2, the workpiece is to be bent through 13 steps, and the offset between the two concentric semi-ellipses is 170 mm, presented in Fig.…”

Section: The Optimum Combinations Of Bending Tool Parametersmentioning

confidence: 99%

Multiple-Step Incremental Air-Bending Forming of High-Strength Sheet Metal Based on Simulation Analysis

2010

Materials and Manufacturing Processes

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The multiple-step incremental air-bending forming of sheet metal is an important and flexible manufacturing process. It is suitable for sheet parts with complex, curved faces. Most research on incremental air-bending forming are mainly based on experiments and explain the process through macroscopic metal deformation. Based on Hill's yielding criterion and exponential strain hardening law as well as plane strain conditions, an analytical model and ABAQUS finite element model (FEM) are proposed in this article for investigating the incremental air-bending forming process. Firstly, the multiple-step incremental air-bending forming processes on different bending tool parameters are simulated with the FEM to analyze the influences of the tool parameters on formed shape, air-bending forming force, and warpage deformation of the workpiece. Then, the multiple-step incremental air-bending forming process of a semi-ellipse-shaped workpiece with 11 535 mm × 574 mm × 453 mm is simulated with FEM established by the optimum tool parameters as well as the optimal process parameters. Manifested by the experiment for incremental air-bending forming of this workpiece, the numerical simulation method proposed yields satisfactory performance in tool parameters optimization and workpiece forming.

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Section: The Optimum Combinations Of Bending Tool Parametersmentioning

confidence: 99%

Multiple-Step Incremental Air-Bending Forming of High-Strength Sheet Metal Based on Simulation Analysis

2010

Materials and Manufacturing Processes

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“…Based on this literature survey two kinds of bend sequence planning methodologies are found: (1) Bend sequence planning methodologies that are aimed to reduce allowable design tolerances for individual bends during the execution of a bending sequence [7,[10][11][12][13][16][17][18][19][20][21][22][23][24] (2) Bend sequence planning methodologies aimed to reduce total bending time by reducing tool and part handling tome, collision avoidance, ergonomic aspects, and geometric constraints [5,11,[25][26][27][28][29][30][31][32][33][34][35][36][37]. It is revealed during this survey that the effects of material and process variations on the overall part accuracy during the execution of a bending sequence is not reported in literature to the best of authors knowledge.…”

Section: Review Of Bending Processmentioning

confidence: 99%

Sheet-metal bend sequence planning subjected to process and material variations

Faraz

Haq

Ali

et al. 2016

Int J Adv Manuf Technol

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CNC press-brake forming is widely used to transform sheet-metal blanks into complex three-dimensional shapes in a low quantity high variety manufacturing environment. Sheet-metal bend sequence planning is a complex combinatorial problem. Process planning and tolerance reasoning for sheet-metal forming are critical to reduce manufacturing time and to address accuracy aspects. Handling time and accuracy of sheet-metal-formed components strongly depend upon the bending sequence. Process and material variations shrink the tolerance zones and therefore their effect must be incorporated in the overall sheet-metal process planning activity. Monte Carlo simulations are used in this article to evaluate the effect of process and material variations on bending accuracy. Branch-and-bound, traveling salesman problem (TSP)-based techniques are used to identify potential feasible bending sequences. Results from the Monte Carlo simulations are used as input for sheet-metal bend sequence planning. In the case study, proposed methodology is used for available industrial sheet-metal components. Resulted tolerance zones attenuated after the probabilistic deflection analysis. Expected error input from probabilistic deflection analysis produced bending sequences which resulted in formed components within designed accuracy limits. Possibility of forming out of tolerance components is also attenuated.

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“…It is a high nonlinear problem containing geometric nonlinear, material nonlinear, and contact nonlinear issues. To solve these issues, the explicit algorithm ABAQUS/Explicit module fitted for dynamic and nonlinear analysis could be used to simulate the sheet metal forming process and the implicit algorithm ABAQUS/Standard module adapted to static and steady analysis to simulate the springback process [1].…”

Section: Numerical Simulation Theorymentioning

confidence: 99%

“…We integrate ABAQUS/Explicit and ABAQUS/Standard to carry out the mixed operations. This method can solve the nonlinear behavior of each step of nonuniform springback in multistep air-bending forming with higher precision and faster convergence [1].…”

Section: Numerical Simulation Theorymentioning

confidence: 99%

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Analysis and elimination for drum warpage of U-shaped workpiece with super length and large opening of sheet metal

Zhao

et al. 2016

Int J Adv Manuf Technol

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To study the mechanism of workpiece warpage under air-bending forming, a method combined experiment with numerical simulation is proposed in this paper. Based on Hill's yielding criterion and plane strain condition, 3D ABAQUS finite element models, used to form the semiellipse-shaped workpiece with super length and large opening of sheet metal, are established. The multistep incremental air-bending forming and nonuniform springback processes are simulated. It is pointed out that a large bending force and bed deformation of press brake can lead to warpage defect of workpiece. A technique used reverse deflection compensation for bed deformation of press brake, and female die with a large opening is found to eliminate warpage defect of workpiece. Manifested by the experiment for incremental air-bending forming of this workpiece, the proposed method yields satisfactory performance in improving forming accuracy and eliminating warpage defect of a large workpiece.

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Study on multiple-step incremental air-bending forming of sheet metal with springback model and FEM simulation

Cited by 19 publications

References 13 publications

Multiple-Step Incremental Air-Bending Forming of High-Strength Sheet Metal Based on Simulation Analysis

Multiple-Step Incremental Air-Bending Forming of High-Strength Sheet Metal Based on Simulation Analysis

Sheet-metal bend sequence planning subjected to process and material variations

Analysis and elimination for drum warpage of U-shaped workpiece with super length and large opening of sheet metal

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