Multi-point forming (MPF) is an advanced manufacturing technology for three-dimensional sheet metal parts. In this paper, the MPF integrated system is described that can form a variety of part shapes without the need ...Multi-point forming (MPF) is an advanced manufacturing technology for three-dimensional sheet metal parts. In this paper, the MPF integrated system is described that can form a variety of part shapes without the need for solid dies, and given only geometry and material information about the desired part. The central component of this system is a pair of matrices of punches, and the desired discrete die surface is constructed by changing the positions of punches though the CAD and control system. The basic MPF process is introduced and the typical application examples show the applicability of the MPF technology. Wrinkle and dimple are the major forming defects in MPF process, numerical simulation is a feasible way to predict forming defects in MPF. In conventional stamping, the mode to form sheet metal with blankholder is an effective way to suppress wrinkling; the same is true in MPF. A MPF press with flexible blankholder was developed, and the forming results indicated the forming stability of this technique. Based on the flexibility of MPF, varying deformation path MPF and sectional MPF were explored that cannot be realized in conventional stamping. By controlling each punch in real-time, a sheet part can be manufactured along a specific forming path. When the path of deformation in MPF is designed properly, forming defects will be avoided completely and lager deformation is achieved. A work piece can be formed section by section though the sectional MPF, and this technique makes it possible to manufacture large size parts in a small MPF press. Some critical experiments were performed that confirmed the validity of two special MPF techniques.展开更多
Sheet metal forming technologies have been intensively studied for decades to meet the increasing demand for lightweight metal components.To surmount the springback occurring in sheet metal forming processes,numerous ...Sheet metal forming technologies have been intensively studied for decades to meet the increasing demand for lightweight metal components.To surmount the springback occurring in sheet metal forming processes,numerous studies have been performed to develop compensation methods.However,for most existing methods,the development cycle is still considerably time-consumptive and demands high computational or capital cost.In this paper,a novel theory-guided regularization method for training of deep neural networks(DNNs),implanted in a learning system,is introduced to learn the intrinsic relationship between the workpiece shape after springback and the required process parameter,e.g.,loading stroke,in sheet metal bending processes.By directly bridging the workpiece shape to the process parameter,issues concerning springback in the process design would be circumvented.The novel regularization method utilizes the well-recognized theories in material mechanics,Swift’s law,by penalizing divergence from this law throughout the network training process.The regularization is implemented by a multi-task learning network architecture,with the learning of extra tasks regularized during training.The stress-strain curve describing the material properties and the prior knowledge used to guide learning are stored in the database and the knowledge base,respectively.One can obtain the predicted loading stroke for a new workpiece shape by importing the target geometry through the user interface.In this research,the neural models were found to outperform a traditional machine learning model,support vector regression model,in experiments with different amount of training data.Through a series of studies with varying conditions of training data structure and amount,workpiece material and applied bending processes,the theory-guided DNN has been shown to achieve superior generalization and learning consistency than the data-driven DNNs,especially when only scarce and scattered experiment data are available for training which is often the case in practice.The theory-guided DNN could also be applicable to other sheet metal forming processes.It provides an alternative method for compensating springback with significantly shorter development cycle and less capital cost and computational requirement than traditional compensation methods in sheet metal forming industry.展开更多
Plasma-jet forming is a newly proposed flexible sheet metal forming process. A non-transferred arc plasma torch is used as a controllable heat source to produce internal stress in sheet metals, causing plastic deforma...Plasma-jet forming is a newly proposed flexible sheet metal forming process. A non-transferred arc plasma torch is used as a controllable heat source to produce internal stress in sheet metals, causing plastic deformation without the necessity of hard tooling. This method has potential for rapid prototyping of sheet metal parts by reducing development costs and lead times. A robotic system has been used to perform simple linear bends in several different alloys. In order to develop a controllable process and to improve the forming accuracy, the effects of various process parameters on the obtained shape changes and on the resulting structure and properties have been studied. The overall goal is to understand the roles of the forming parameters and their inter-relationship in optimizing the forming procedure-a high forming speed without damage to the material structure or properties.展开更多
Intellectualization of sheet metal in deep drawing is a new combined technology, which is concerned with control science and computer science and sheet metal forming theory. The intelligent control system for sheet me...Intellectualization of sheet metal in deep drawing is a new combined technology, which is concerned with control science and computer science and sheet metal forming theory. The intelligent control system for sheet metal deep drawing consists of four fundamental factors: real time measurement, identification, prediction and control. Real time identification of material properties and friction coefficient is the most important factor in the whole system. An artificial neural network model for identification of the material properties and friction coefficient was established according to deep drawing characteristics and more automation. The identification of the material properties and friction coefficient was realized.展开更多
This paper presented a model of integrated reverse engineering system and set up its various data output flowchart, which is easy to be associated with other systems. The idea of integrated reverse engineer is introdu...This paper presented a model of integrated reverse engineering system and set up its various data output flowchart, which is easy to be associated with other systems. The idea of integrated reverse engineer is introduced to the system of forming sheet metal with complex surface and using IDEF0 method sets up the function model of the system. The freeform surface reconstruction and CAD modeling of the system are described and decomposed. This paper discussed some problems, such as the feature expression, feature modeling and feature translation of the sheet parts and dies.展开更多
This paper presents the derivation of a first order friction model for lubricated sheet metal forming.Assuming purely plastic real contacts, Newton's law of viscosity, and a square root behavior of the hydrodynami...This paper presents the derivation of a first order friction model for lubricated sheet metal forming.Assuming purely plastic real contacts, Newton's law of viscosity, and a square root behavior of the hydrodynamic coefficient of friction with respect to the hydrodynamic Hersey parameter an analytic model is found. The model predicts the coefficient of friction as a function of the relative pressure, the relative Hersey parameter and the real contact coefficient of friction. Questions about local and global friction are raised in the validation of the model against flat tool sheet experiments. For some flat tool sheet experiments reasonable agreements are obtained assuming a rigid punch pressure distribution. The restricted number of user inputs makes the model useful in early tool design simulations.展开更多
A commercially available laser marking system based on diode-pumped Nd:YVO<sub>4</sub> laser was used for creating grid patterns for forming strain analysis of a dual-phase steel. The aim was to determine ...A commercially available laser marking system based on diode-pumped Nd:YVO<sub>4</sub> laser was used for creating grid patterns for forming strain analysis of a dual-phase steel. The aim was to determine and analyze the influence of laser working parameters on the formability of sheet material by means of an in-depth characterization of this induced microstructural and geometric inhomogeneity. The electrochemical etching served as the reference method without the negative effect of generating inhomogeneity. The formability was evaluated using the cupping test according to Erichsen. While the quantification of geometric inhomogeneity was based on the determination of the notch factor, light microscopy and microhardness measurement were used for the evaluation of microstructural inhomogeneity. Furthermore, on the basis of the results an empirical regression model was established which described in terms of quantity the relationship between the examined factors such as laser power, pulse frequency and scanning speed as well as the command variable and the mark depth. The results showed that microstructural inhomogeneity in the used marking parameters due to their locally very limited formation did not have an appreciable influence on the mechanical properties. In contrast to this, the induced geometric inhomogeneity had a marked influence on the material formability.展开更多
In sheet metal forming, drawbeads are often used to control uneven material flow which may cause defects such as wrinkles, fracture, surface distortion and springback. Appropriate setting and adjusting the drawbead fo...In sheet metal forming, drawbeads are often used to control uneven material flow which may cause defects such as wrinkles, fracture, surface distortion and springback. Appropriate setting and adjusting the drawbead force is one of the most important pa- rameters in sheet metal forming process control. This paper derives the model of loop drawbead restraining force (DBRF) using plastic forming theory, and gives the min imum blankholding force. Experiments are carried out to verify the proposed DBRF model. The good agreement between the calculated values and experiments data justi- fies the proposed loop drawbead restraining force model.展开更多
Surrogate assisted optimization has been widely applied in sheet metal forming design due to its efficiency. Therefore, to improve the efficiency of design and reduce the product development cycle, it is important for...Surrogate assisted optimization has been widely applied in sheet metal forming design due to its efficiency. Therefore, to improve the efficiency of design and reduce the product development cycle, it is important for scholars and engineers to have some insight into the performance of each surrogate assisted optimization method and make them more flexible practically. For this purpose, the state-of-the-art surrogate assisted optimizations are investigated. Furthermore, in view of the bottleneck and development of the surrogate assisted optimization and sheet metal forming design, some important issues on the surrogate assisted optimization in support of the sheet metal forming design are analyzed and discussed, involving the description of the sheet metal forming design, off-line and online sampling strategies, space mapping algorithm, high dimensional problems, robust design, some challenges and potential feasible methods. Generally, this paper provides insightful observations into the performance and potential development of these methods in sheet metal forming design.展开更多
The experimental die apparatus of the solid granules medium forming on sheet metal was designed and manufactured.Typical parts,such as conical,parabolic,cylindrical and square-box-shaped components,were successfully t...The experimental die apparatus of the solid granules medium forming on sheet metal was designed and manufactured.Typical parts,such as conical,parabolic,cylindrical and square-box-shaped components,were successfully trial-produced as well.According to the analysis of the changing trends of the cross-section shape and the wall thickness during the process,it can be found that the shape of the free deformation zone of the sheet metal,which is the most critical thinning area,can be described as an approximately spherical cap.According to this forming feature,back pressure deep drawing technology with solid granules medium on sheet metal was proposed to restrain drastic thinning at the bottom of the part through the joint friction effect of solid granules medium,the back pressure tringle and the sheet metal.Therefore,the deep drawing limit of the sheet metal is significantly improved.In order to fabricate thin-walled rotary parts with great drawing ratio and complex cross-sections,a finite element model based on the material property test of the solid granules medium was established to optimize the scheme of the back pressure deep drawing.The effects on the forming performance of sheet metal from back pressure load and the approach of blank holding control were analyzed through this model.展开更多
By using the Finite Element Inverse Approach based on the Hill quadratic anisotropically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The b...By using the Finite Element Inverse Approach based on the Hill quadratic anisotropically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results,respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.展开更多
The use of ultra-high strength steels through sheet metal forming process offers a practical solution to the lightweight design of vehicles.However,sheet metal forming process not only produces desirable changes in ma...The use of ultra-high strength steels through sheet metal forming process offers a practical solution to the lightweight design of vehicles.However,sheet metal forming process not only produces desirable changes in material properties but also causes material damage that may adversely influence the service performance of the material formed.Thus,an investigation is conducted to experimentally quantify such influence for a commonly used steel(the 22MnB5 steel) based on the hot and cold forming processes.For each process,a number of samples are used to conduct a uniaxial tensile test to simulate the forming process.After that,some of the samples are trimmed into a standard shape and then uniaxially extended until fracture to simulate the service stage.Finally,a microstructure test is conducted to analyze the microdefects of the remaining samples.Based on the results of the first two tests,the effect of material damage on the service performance of 22MnB5 steel is analyzed.It is found that the material damages of both the hot and cold forming processes cause reductions in the service performance,such as the failure strain,the ultimate stress,the capacity of energy absorption and the ratio of residual strain.The reductions are generally lower and non-linear in the former process but higher and linear in the latter process.Additionally,it is found from the microstructure analysis that the difference in the reductions of the service performance of 22MnB5 by the two forming processes is driven by the difference in the micro damage mechanisms of the two processes.The findings of this research provide a useful reference in terms of the selection of sheet metal forming processes and the determination of forming parameters for 22MnB5.展开更多
Based on the elastic-plastic large deformation finite element formulation as well as the shell element combined discrete Kirchhoff theoretical plate element (DKT) with membrane square element, deep-drawing bending spr...Based on the elastic-plastic large deformation finite element formulation as well as the shell element combined discrete Kirchhoff theoretical plate element (DKT) with membrane square element, deep-drawing bending springback of typical U-pattern is studied.At the same time the springback values of the drawing of patterns' unloading and trimming about the satellite aerial reflecting surface are predicted and also compared with those of the practical punch.Above two springbacks all obtain satisfactory results, which provide a kind of effective quantitative pre-prediction of springback for the practical engineers.展开更多
To investigate the influence of magnitude and distribution of the transverse normal pressure on deformation behavior of sheet metal,viscous pressure bulge test (VPB) of overlapping sheet metals is proposed,where the o...To investigate the influence of magnitude and distribution of the transverse normal pressure on deformation behavior of sheet metal,viscous pressure bulge test (VPB) of overlapping sheet metals is proposed,where the overlapped sheet metal is deformed under the dual-sided normal pressure provided by viscous medium and the overlapping sheet.The transverse normal pressure loading features provided by overlapping sheet metals are first simulated by DEFORM-2D.It shows that the magnitude and space distribution of transverse normal pressure are dependent on strain hardening exponent n-,strength coefficient K-and thickness t-values of the overlapping sheet metal.Based on the stress,deviator stress and strain distribution resulted from the finite element simulation,it indicated that the uniform transverse normal pressure has no effect on deviator stress,the figure and strain distribution of bulge specimens have no change.The non-uniform transverse normal pressure can remarkably change the figure and metal flow of specimens,and the formability of sheet metal can be improved by controlling the transverse normal pressure distribution.展开更多
In modern manufacturing,a new type of sheet metal part with step cross-section in both inner hole and outer edge is proposed.The traditional stamping separating processes can only produce sheet metal part with vertica...In modern manufacturing,a new type of sheet metal part with step cross-section in both inner hole and outer edge is proposed.The traditional stamping separating processes can only produce sheet metal part with vertical cross-section.According to the latest developing theory and potential of cold pressure forming:combination of pressure and cold forging,a new flow control forming of sheet metal(FCF) is excogitated based on blanking process of general stamping and combined with cold forging processes such as extrusion and coining,etc,which is aiming at the above-mentioned new type of sheet metal part.With utilization of this new process,the new type of sheet metal parts can be manufactured.In order to shorten the testing period,the numerical simulation was carried out by using DEFORM-3D software,and both deformation and mechanics rules were analyzed.Based on the simulation,both punching part and blanked parts of this new type were successfully developed.Then a new conception of optimal distance between the step walls of inner hole and outside edge was proposed and the design principle for its numerical value was inferred.Furthermore,a mold set for combination of stamping & cold forging was designed and manufactured,by which the technologic experiments were taken for validation with Aluminum plate of thickness 2.35 mm for power battery cover board,which verified the principle of the distance between the step walls.The research of cold pressure forming of thin sheet metal with step cross-section is significant,not only to the development of modern mechanical manufacture,but also to metal plastic forming science.展开更多
U-channel forming tests were performed to investigate the surface topography evolvement of hot-dip galvanized(GI) and galvannealed(GA) steels and the effects of die hardness on sheet metal forming(SMF). Experimental r...U-channel forming tests were performed to investigate the surface topography evolvement of hot-dip galvanized(GI) and galvannealed(GA) steels and the effects of die hardness on sheet metal forming(SMF). Experimental results indicate that the surface roughness values of the two galvanized steels increase with the number of forming,i.e.,the surface topographies of galvanized steels are roughened in SMF. Moreover,GI steel has a better ability of damage-resistance than GA steel. The mechanisms of topography evolvement are different in the forming of GI and GA steels. Scratch is the main form of surface damage in the forming of GI steels. The severity of scratch can be decreased by increasing die hardness. GA steel results in exfoliating of the coating firstly and then severe scratching. The surface topography of galvannealed steels can be improved by increasing die hardness. However,the hardness should not be too high.展开更多
Blank holder force (BHF) is an important measure to control the sheet metal forming.BHF is identified quickly using artificial neural network (ANN) on the basis of itsanalytical description. And critical rupture and w...Blank holder force (BHF) is an important measure to control the sheet metal forming.BHF is identified quickly using artificial neural network (ANN) on the basis of itsanalytical description. And critical rupture and wrinkle BHF curves are given. Aclose-loop control system is established to finish the forming process.展开更多
Single-point incremental forming (SPIF) is an innovational sheet metal forming method without dedicated dies,which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal,the deformation analy...Single-point incremental forming (SPIF) is an innovational sheet metal forming method without dedicated dies,which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal,the deformation analysis on forming process becomes an important and useful method for the planning of shell products,the choice of material,the design of the forming process and the planning of the forming tool. Using solid brick elements,the finite element method(FEM) model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation,the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then,according to the simulated forming process,the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters' impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing,the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing,the plastic deformation zone increases and the forming force will be bigger.展开更多
Based on the Finite Element Theory of Rigid Plastic, relevant problems during plastic simulation on sheet metal forming were technologically studied and simplified; a simplified model of the blank holder during the dr...Based on the Finite Element Theory of Rigid Plastic, relevant problems during plastic simulation on sheet metal forming were technologically studied and simplified; a simplified model of the blank holder during the drawing process was established and the effects of related parameters on the forming processes were also studied. At the same time, a finite-element numerical simulation program SPID was developed. The distribution of strain and relationship of stress-stroke simulated were compared with experimented, the results are well coincided with each other. It is verified that the analytical program is reliable.展开更多
文摘Multi-point forming (MPF) is an advanced manufacturing technology for three-dimensional sheet metal parts. In this paper, the MPF integrated system is described that can form a variety of part shapes without the need for solid dies, and given only geometry and material information about the desired part. The central component of this system is a pair of matrices of punches, and the desired discrete die surface is constructed by changing the positions of punches though the CAD and control system. The basic MPF process is introduced and the typical application examples show the applicability of the MPF technology. Wrinkle and dimple are the major forming defects in MPF process, numerical simulation is a feasible way to predict forming defects in MPF. In conventional stamping, the mode to form sheet metal with blankholder is an effective way to suppress wrinkling; the same is true in MPF. A MPF press with flexible blankholder was developed, and the forming results indicated the forming stability of this technique. Based on the flexibility of MPF, varying deformation path MPF and sectional MPF were explored that cannot be realized in conventional stamping. By controlling each punch in real-time, a sheet part can be manufactured along a specific forming path. When the path of deformation in MPF is designed properly, forming defects will be avoided completely and lager deformation is achieved. A work piece can be formed section by section though the sectional MPF, and this technique makes it possible to manufacture large size parts in a small MPF press. Some critical experiments were performed that confirmed the validity of two special MPF techniques.
基金supported by Aviation Industry Corporation of China(AVIC)Manufacturing Technology Institute(MTI)and in part by China Scholarship Council(CSC)(201908060236)。
文摘Sheet metal forming technologies have been intensively studied for decades to meet the increasing demand for lightweight metal components.To surmount the springback occurring in sheet metal forming processes,numerous studies have been performed to develop compensation methods.However,for most existing methods,the development cycle is still considerably time-consumptive and demands high computational or capital cost.In this paper,a novel theory-guided regularization method for training of deep neural networks(DNNs),implanted in a learning system,is introduced to learn the intrinsic relationship between the workpiece shape after springback and the required process parameter,e.g.,loading stroke,in sheet metal bending processes.By directly bridging the workpiece shape to the process parameter,issues concerning springback in the process design would be circumvented.The novel regularization method utilizes the well-recognized theories in material mechanics,Swift’s law,by penalizing divergence from this law throughout the network training process.The regularization is implemented by a multi-task learning network architecture,with the learning of extra tasks regularized during training.The stress-strain curve describing the material properties and the prior knowledge used to guide learning are stored in the database and the knowledge base,respectively.One can obtain the predicted loading stroke for a new workpiece shape by importing the target geometry through the user interface.In this research,the neural models were found to outperform a traditional machine learning model,support vector regression model,in experiments with different amount of training data.Through a series of studies with varying conditions of training data structure and amount,workpiece material and applied bending processes,the theory-guided DNN has been shown to achieve superior generalization and learning consistency than the data-driven DNNs,especially when only scarce and scattered experiment data are available for training which is often the case in practice.The theory-guided DNN could also be applicable to other sheet metal forming processes.It provides an alternative method for compensating springback with significantly shorter development cycle and less capital cost and computational requirement than traditional compensation methods in sheet metal forming industry.
文摘Plasma-jet forming is a newly proposed flexible sheet metal forming process. A non-transferred arc plasma torch is used as a controllable heat source to produce internal stress in sheet metals, causing plastic deformation without the necessity of hard tooling. This method has potential for rapid prototyping of sheet metal parts by reducing development costs and lead times. A robotic system has been used to perform simple linear bends in several different alloys. In order to develop a controllable process and to improve the forming accuracy, the effects of various process parameters on the obtained shape changes and on the resulting structure and properties have been studied. The overall goal is to understand the roles of the forming parameters and their inter-relationship in optimizing the forming procedure-a high forming speed without damage to the material structure or properties.
文摘Intellectualization of sheet metal in deep drawing is a new combined technology, which is concerned with control science and computer science and sheet metal forming theory. The intelligent control system for sheet metal deep drawing consists of four fundamental factors: real time measurement, identification, prediction and control. Real time identification of material properties and friction coefficient is the most important factor in the whole system. An artificial neural network model for identification of the material properties and friction coefficient was established according to deep drawing characteristics and more automation. The identification of the material properties and friction coefficient was realized.
基金The Research Fund for the Doctoral Pro- gram of Higher Education( 2 0 0 0 0 2 4838)
文摘This paper presented a model of integrated reverse engineering system and set up its various data output flowchart, which is easy to be associated with other systems. The idea of integrated reverse engineer is introduced to the system of forming sheet metal with complex surface and using IDEF0 method sets up the function model of the system. The freeform surface reconstruction and CAD modeling of the system are described and decomposed. This paper discussed some problems, such as the feature expression, feature modeling and feature translation of the sheet parts and dies.
基金supported by the Swedish Foundation for Strategic Research(PV08-0041)
文摘This paper presents the derivation of a first order friction model for lubricated sheet metal forming.Assuming purely plastic real contacts, Newton's law of viscosity, and a square root behavior of the hydrodynamic coefficient of friction with respect to the hydrodynamic Hersey parameter an analytic model is found. The model predicts the coefficient of friction as a function of the relative pressure, the relative Hersey parameter and the real contact coefficient of friction. Questions about local and global friction are raised in the validation of the model against flat tool sheet experiments. For some flat tool sheet experiments reasonable agreements are obtained assuming a rigid punch pressure distribution. The restricted number of user inputs makes the model useful in early tool design simulations.
文摘A commercially available laser marking system based on diode-pumped Nd:YVO<sub>4</sub> laser was used for creating grid patterns for forming strain analysis of a dual-phase steel. The aim was to determine and analyze the influence of laser working parameters on the formability of sheet material by means of an in-depth characterization of this induced microstructural and geometric inhomogeneity. The electrochemical etching served as the reference method without the negative effect of generating inhomogeneity. The formability was evaluated using the cupping test according to Erichsen. While the quantification of geometric inhomogeneity was based on the determination of the notch factor, light microscopy and microhardness measurement were used for the evaluation of microstructural inhomogeneity. Furthermore, on the basis of the results an empirical regression model was established which described in terms of quantity the relationship between the examined factors such as laser power, pulse frequency and scanning speed as well as the command variable and the mark depth. The results showed that microstructural inhomogeneity in the used marking parameters due to their locally very limited formation did not have an appreciable influence on the mechanical properties. In contrast to this, the induced geometric inhomogeneity had a marked influence on the material formability.
文摘In sheet metal forming, drawbeads are often used to control uneven material flow which may cause defects such as wrinkles, fracture, surface distortion and springback. Appropriate setting and adjusting the drawbead force is one of the most important pa- rameters in sheet metal forming process control. This paper derives the model of loop drawbead restraining force (DBRF) using plastic forming theory, and gives the min imum blankholding force. Experiments are carried out to verify the proposed DBRF model. The good agreement between the calculated values and experiments data justi- fies the proposed loop drawbead restraining force model.
基金Supported by National Natural Science Foundation of China(Grant Nos.11572120,11172097,11302266)
文摘Surrogate assisted optimization has been widely applied in sheet metal forming design due to its efficiency. Therefore, to improve the efficiency of design and reduce the product development cycle, it is important for scholars and engineers to have some insight into the performance of each surrogate assisted optimization method and make them more flexible practically. For this purpose, the state-of-the-art surrogate assisted optimizations are investigated. Furthermore, in view of the bottleneck and development of the surrogate assisted optimization and sheet metal forming design, some important issues on the surrogate assisted optimization in support of the sheet metal forming design are analyzed and discussed, involving the description of the sheet metal forming design, off-line and online sampling strategies, space mapping algorithm, high dimensional problems, robust design, some challenges and potential feasible methods. Generally, this paper provides insightful observations into the performance and potential development of these methods in sheet metal forming design.
基金Project(50775197) supported by the National Natural Science Foundation of China
文摘The experimental die apparatus of the solid granules medium forming on sheet metal was designed and manufactured.Typical parts,such as conical,parabolic,cylindrical and square-box-shaped components,were successfully trial-produced as well.According to the analysis of the changing trends of the cross-section shape and the wall thickness during the process,it can be found that the shape of the free deformation zone of the sheet metal,which is the most critical thinning area,can be described as an approximately spherical cap.According to this forming feature,back pressure deep drawing technology with solid granules medium on sheet metal was proposed to restrain drastic thinning at the bottom of the part through the joint friction effect of solid granules medium,the back pressure tringle and the sheet metal.Therefore,the deep drawing limit of the sheet metal is significantly improved.In order to fabricate thin-walled rotary parts with great drawing ratio and complex cross-sections,a finite element model based on the material property test of the solid granules medium was established to optimize the scheme of the back pressure deep drawing.The effects on the forming performance of sheet metal from back pressure load and the approach of blank holding control were analyzed through this model.
基金Project supported by the National Natural Sciences Foundation of China(No. 50335060).
文摘By using the Finite Element Inverse Approach based on the Hill quadratic anisotropically yield criterion and the quadrilateral element, a fast analyzing software-FASTAMP for the sheet metal forming is developed. The blank shapes of three typical stampings are simulated and compared with numerical results given by the AUTOFORM software and experimental results,respectively. The comparison shows that the FASTAMP can predict blank shape and strain distribution of the stamping more precisely and quickly than those given by the traditional methods and the AUTOFORM.
基金Supported by National Natural Science Foundation of China(Grant No.51375201)CSAE(Beijing)Automotive Lightweight Technology Research Institute Development Fund Project of China
文摘The use of ultra-high strength steels through sheet metal forming process offers a practical solution to the lightweight design of vehicles.However,sheet metal forming process not only produces desirable changes in material properties but also causes material damage that may adversely influence the service performance of the material formed.Thus,an investigation is conducted to experimentally quantify such influence for a commonly used steel(the 22MnB5 steel) based on the hot and cold forming processes.For each process,a number of samples are used to conduct a uniaxial tensile test to simulate the forming process.After that,some of the samples are trimmed into a standard shape and then uniaxially extended until fracture to simulate the service stage.Finally,a microstructure test is conducted to analyze the microdefects of the remaining samples.Based on the results of the first two tests,the effect of material damage on the service performance of 22MnB5 steel is analyzed.It is found that the material damages of both the hot and cold forming processes cause reductions in the service performance,such as the failure strain,the ultimate stress,the capacity of energy absorption and the ratio of residual strain.The reductions are generally lower and non-linear in the former process but higher and linear in the latter process.Additionally,it is found from the microstructure analysis that the difference in the reductions of the service performance of 22MnB5 by the two forming processes is driven by the difference in the micro damage mechanisms of the two processes.The findings of this research provide a useful reference in terms of the selection of sheet metal forming processes and the determination of forming parameters for 22MnB5.
基金This project is supported by National Natural Science Foundation of China (No.19832020)Provincial Natural Science Foundation of Jilin (No.20000519)
文摘Based on the elastic-plastic large deformation finite element formulation as well as the shell element combined discrete Kirchhoff theoretical plate element (DKT) with membrane square element, deep-drawing bending springback of typical U-pattern is studied.At the same time the springback values of the drawing of patterns' unloading and trimming about the satellite aerial reflecting surface are predicted and also compared with those of the practical punch.Above two springbacks all obtain satisfactory results, which provide a kind of effective quantitative pre-prediction of springback for the practical engineers.
文摘To investigate the influence of magnitude and distribution of the transverse normal pressure on deformation behavior of sheet metal,viscous pressure bulge test (VPB) of overlapping sheet metals is proposed,where the overlapped sheet metal is deformed under the dual-sided normal pressure provided by viscous medium and the overlapping sheet.The transverse normal pressure loading features provided by overlapping sheet metals are first simulated by DEFORM-2D.It shows that the magnitude and space distribution of transverse normal pressure are dependent on strain hardening exponent n-,strength coefficient K-and thickness t-values of the overlapping sheet metal.Based on the stress,deviator stress and strain distribution resulted from the finite element simulation,it indicated that the uniform transverse normal pressure has no effect on deviator stress,the figure and strain distribution of bulge specimens have no change.The non-uniform transverse normal pressure can remarkably change the figure and metal flow of specimens,and the formability of sheet metal can be improved by controlling the transverse normal pressure distribution.
文摘In modern manufacturing,a new type of sheet metal part with step cross-section in both inner hole and outer edge is proposed.The traditional stamping separating processes can only produce sheet metal part with vertical cross-section.According to the latest developing theory and potential of cold pressure forming:combination of pressure and cold forging,a new flow control forming of sheet metal(FCF) is excogitated based on blanking process of general stamping and combined with cold forging processes such as extrusion and coining,etc,which is aiming at the above-mentioned new type of sheet metal part.With utilization of this new process,the new type of sheet metal parts can be manufactured.In order to shorten the testing period,the numerical simulation was carried out by using DEFORM-3D software,and both deformation and mechanics rules were analyzed.Based on the simulation,both punching part and blanked parts of this new type were successfully developed.Then a new conception of optimal distance between the step walls of inner hole and outside edge was proposed and the design principle for its numerical value was inferred.Furthermore,a mold set for combination of stamping & cold forging was designed and manufactured,by which the technologic experiments were taken for validation with Aluminum plate of thickness 2.35 mm for power battery cover board,which verified the principle of the distance between the step walls.The research of cold pressure forming of thin sheet metal with step cross-section is significant,not only to the development of modern mechanical manufacture,but also to metal plastic forming science.
基金Project(50605043) supported by the National Natural Science Foundation of China
文摘U-channel forming tests were performed to investigate the surface topography evolvement of hot-dip galvanized(GI) and galvannealed(GA) steels and the effects of die hardness on sheet metal forming(SMF). Experimental results indicate that the surface roughness values of the two galvanized steels increase with the number of forming,i.e.,the surface topographies of galvanized steels are roughened in SMF. Moreover,GI steel has a better ability of damage-resistance than GA steel. The mechanisms of topography evolvement are different in the forming of GI and GA steels. Scratch is the main form of surface damage in the forming of GI steels. The severity of scratch can be decreased by increasing die hardness. GA steel results in exfoliating of the coating firstly and then severe scratching. The surface topography of galvannealed steels can be improved by increasing die hardness. However,the hardness should not be too high.
文摘Blank holder force (BHF) is an important measure to control the sheet metal forming.BHF is identified quickly using artificial neural network (ANN) on the basis of itsanalytical description. And critical rupture and wrinkle BHF curves are given. Aclose-loop control system is established to finish the forming process.
基金supported by National Natural Science Foundation of China(No. 50175034).
文摘Single-point incremental forming (SPIF) is an innovational sheet metal forming method without dedicated dies,which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal,the deformation analysis on forming process becomes an important and useful method for the planning of shell products,the choice of material,the design of the forming process and the planning of the forming tool. Using solid brick elements,the finite element method(FEM) model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation,the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then,according to the simulated forming process,the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters' impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing,the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing,the plastic deformation zone increases and the forming force will be bigger.
文摘Based on the Finite Element Theory of Rigid Plastic, relevant problems during plastic simulation on sheet metal forming were technologically studied and simplified; a simplified model of the blank holder during the drawing process was established and the effects of related parameters on the forming processes were also studied. At the same time, a finite-element numerical simulation program SPID was developed. The distribution of strain and relationship of stress-stroke simulated were compared with experimented, the results are well coincided with each other. It is verified that the analytical program is reliable.
