Abstract
Three-dimensional sheet metal forming is one of the biggest challenges in the shipbuilding industry. The forming quality of the traditionally applied line heating method depends entirely on the skills of the technicians. Moreover, this approach is inefficient and error-prone. This calls for a need to develop new forming technologies that are easy to control and more efficient. In this paper, a novel forming method called heat-assisted incremental bending is presented. The minimum energy loading path of bidirectional curvature sheet along the direction of Gaussian curvature is adapted to deform the sheet metals with a convex shape surface. Besides, the auxiliary heating method and the auxiliary supporting are exclusively included in the forming process to improve the formability and accuracy. In this study, the convex-shaped sheet metal with large curvature is obtained along the two loading trajectories in two principal curvature directions, respectively. Results proved that using the minimum energy loading trajectory and including the auxiliary supports and heating can reduce the forming force to the greatest extent and effectively reduce the number of stamping points, thus improving the sheet metal forming efficiency and forming accuracy.
Issue Section:
Research Papers
Keywords:
line heating method,
heat-assisted incremental bending,
convex-shaped sheet metal,
springback,
minimum energy loading trajectory,
control and automation,
design for manufacturing,
nontraditional manufacturing processes,
sheet and tube metal forming
Topics:
Deformation,
Heat,
Heating,
Metal stamping,
Sheet metal,
Trajectories (Physics),
Simulation,
Errors,
Temperature,
Shapes
References
1.
Li
, M. Z.
, Cai
, Z. Y.
, Sui
, Z.
, and Yan
, Q. G.
, 2002
, “Multi-Point Forming Technology for Sheet Metal
,” J. Mater. Process. Technol.
, 129
(1
), pp. 333
–338
.2.
Liu
, C. G.
, Li
, M. Z.
, and Fu
, W. Z.
, 2008
, “Principles and Apparatus of Multi-point Forming for Sheet Metal
,” Int. J. Adv. Manuf. Technol.
, 35
(11–12
), pp. 1227
–1233
. 3.
He
, L. P.
, Li
, M. Z.
, Liu
, C. G.
, and Cao
, J.
, 2013
, “Study of Multi-Point Forming for Polycarbonate Sheet
,” Int. J. Adv. Manuf. Technol.
, 67
(9–12
), pp. 2811
–2817
.4.
Liu
, Y. J.
, Li
, M. Z.
, and Ju
, F. F.
, 2017
, “Research on the Process of Flexible Blank Holder in Multi-point Forming for Spherical Surface Parts
,” Int. J. Adv. Manuf. Technol.
, 89
(5–8
), pp. 2315
–2322
. 5.
Chen
, J.
, Fu
, W. Z.
, and Li
, M. Z.
, 2017
, “Local Bending Effect and Its Controlling Methods in Multi-point Forming
,” Int. J. Adv. Manuf. Technol.
, 92
(9–12
), pp. 4315
–4322
. 6.
Qu
, E. H.
, Li
, M. Z.
, Li
, R.
, Liang
, Z.
, and Zhuo
, Y.
, 2018
, “Inhibitory Effects of a Flexible Steel Pad on Wrinkling in Multi-point Die Forming
,” Int. J. Adv. Manuf. Technol.
, 95
(5–8
), pp. 2413
–2420
.7.
Qu
, E. H.
, Li
, M. Z.
, Li
, R.
, Cui
, M. Y.
, and Lin
, J. L.
, 2018
, “Research on Formability in Multi-point Forming With Different Elastic Pads
,” Int. J. Adv. Manuf. Technol.
, 98
(5–8
), pp. 1887
–1901
.8.
Cui
, M. Y.
, Li
, M. Z.
, Qu
, E. H.
, Zheng
, C. Y.
, and Sun
, Y. M.
, 2018
, “Research on Transition Region in Sectional Multi-point Forming of Saddle-Shaped Parts
,” Int. J. Adv. Manuf. Technol.
, 96
(9–12
), pp. 4445
–4453
. 9.
Su
, S. J.
, Hu
, Y.
, and Wang
, C. F.
, 2015
, “The Key Technology Research About 3D CNC Bending Machine and Experimental Verification
,” J. Coastal. Res.
, 73
(73
), pp. 584
–588
. 10.
Luo
, Y. X.
, Yang
, W. M.
, Liu
, Z. F.
, Wang
, Y. Q.
, and Du
, R. X.
, 2016
, “Numerical Simulation and Experimental Study on Cyclic Multi-point Incremental Forming Process
,” Int. J. Adv. Manuf. Technol.
, 85
(5–8
), pp. 1249
–1259
. 11.
Shim
, D. S.
, Yang
, D. Y.
, Kim
, K. H.
, Han
, M. S.
, and Chuang
, S. W.
, 2009
, “Numerical and Experimental Investigation Into Cold Incremental Rolling of Doubly Curved Plates for Process Design of a New LARS (Line Array Roll Set) Rolling Process
,” CIRP Ann. Manuf. Technol.
, 58
(1
), pp. 239
–242
. 12.
Shim
, D. S.
, Yang
, D. Y.
, Kim
, K. H.
, Chung
, S. W.
, and Han
, M. S.
, 2010
, “Investigation Into Forming Sequences for the Incremental Forming of Doubly Curved Plates Using the Line Array Roll Set Process
,” Int. J. Mach. Tool. Manuf.
, 50
(2
), pp. 214
–218
. 13.
Cai
, Z. Y.
, Li
, M. Z.
, and Lan
, Y. W.
, 2012
, “Three-Dimensional Sheet Metal Continuous Forming Process Based on Flexible Roll Bending: Principle and Experiments
,” J. Mater. Process. Technol.
, 212
(1
), pp. 120
–127
. 14.
Cai
, Z. Y.
, Li
, L. L.
, and Wang
, M.
, 2014
, “Process Design and Longitudinal Deformation Prediction in Continuous Sheet Metal Roll Forming for Three-Dimensional Surface
,” Int. J. Precis. Eng. Manuf.
, 15
(9
), pp. 1889
–1895
. 15.
Li
, R. J.
, Li
, M. Z.
, Qiu
, N. J.
, and Cai
, Z. W.
, 2014
, “Surface Flexible Rolling for Three-Dimensional Sheet Metal Parts
,” J. Mater. Process. Technol.
, 214
(2
), pp. 380
–389
. 16.
Tavakoli
, A.
, Naeini
, H. M.
, Roohi
, A. H.
, Gollo
, M. H.
, and Shahabad
, S. I.
, 2017
, “Determining Optimized Radial Scan Path in 3D Laser Forming of Steel AISI 304 Plates to Produce Bowl Shapes
,” Int. J. Adv. Manuf. Technol.
, 91
(9–12
), pp. 3457
–3465
. 17.
Yang
, L. J.
, Wang
, M. L.
, Wang
, Y.
, and Chen
, Y. B.
, 2010
, “Dynamic Analysis on Laser Forming of Square Metal Sheet to Spherical Dome
,” Int. J. Adv. Manuf. Technol.
, 51
(5–8
), pp. 519
–539
. 18.
Shahabad
, S. I.
, Naeini
, H. M.
, Roohi
, A. H.
, Tavakoli
, A.
, and Nasrollahzade
, M.
, 2017
, “Experimental Investigation of Laser Forming Process to Produce Dome-Shaped Products
,” Int. J. Adv. Manuf. Technol.
, 90
(1–4
), pp. 1051
–1057
. 19.
Liu
, C.
, and Yao
, Y. L.
, 2005
, “FEM-Based Process Design for Laser Forming of Doubly Curved Shapes
,” J. Mater. Process. Technol.
, 7
(2
), pp. 109
–121
.20.
Chakraborty
, S. S.
, More
, H.
, and Nath
, A. K.
, 2016
, “Laser Forming of a Bowl Shaped Surface With a Stationary Laser Beam
,” Opt. Laser. Eng.
, 77
, pp. 126
–136
. 21.
Hong
, S.
, Zhou
, W. T.
, and Wang
, H.
, 2018
, “Laser Forming of Doubly Curved Plates Using Minimum Energy Principle and Comprehensive Strain Control
,” Int. J. Mech. Sci.
, 145
, pp. 42
–52
.22.
Xu
, L.
, Li
, W. D.
, and Wan
, M.
, 2015
, “Laser Bending Process of Preloaded Sheet Metal
,” MATEC Web of Conferences
, Vol. 21
, pp. 1
–7
. 23.
Yanjin
, G.
, Sheng
, S.
, Guoqun
, Z.
, and Yiguo
, L.
, 2003
, “Finite Element Modeling of Laser Bending of Pre-Loaded Sheet Metals
,” J. Mater. Process. Technol.
, 142
(2
), pp. 400
–407
. 24.
Yao
, Z. Q.
, Hong
, S.
, Shi
, Y. J.
, and Hu
, J.
, 2007
, “Numerical Study on Laser Forming of Sheet Metals With Pre-Loads. Comp
,” Mater. Sci.
, 40
(1
), pp. 27
–32
.25.
Wang
, C. T.
, Kinzel
, G.
, and Altan
, T.
, 1993
, “Mathematical Modeling of Plane-Strain Bending of Sheet and Plate
,” J. Mater. Process. Technol.
, 39
(3
), pp. 279
–304
. 26.
Yang
, X.
, Choi
, C.
, Sever
, N. K.
, and Altan
, T.
, 2016
, “Prediction of Springback in Air-Bending of Advanced High Strength Steel (DP780) Considering Young’s Modulus Variation and With a Piecewise Hardening Function
,” Int. J. Mech. Sci.
, 105
, pp. 266
–272
. 27.
Khadra
, F. A.
, and Elmorsy
, A. W.
, 2016
, “Prediction of Springback in the Air Bending Process Using a Kriging Metamodel
,” Eng. Technol. Appl. Sci.
, 6
(5
), pp. 1200
–1206
. 28.
Johnson
, W.
, and Yu
, T. X.
, 1981
, “Springback After the Biaxial Elastic-Plastic Pure Bending of a Rectangular Plate-I
,” Int. J. Mech. Sci.
, 23
(10
), pp. 619
–630
. 29.
Borah
, U.
, Venugopal
, S.
, Nagarajan
, R.
, Sivaprasad
, P. V.
, Venugopal
, S.
, and Raj
, B.
, 2008
, “Estimation of Springback in Double-Curvature Forming of Plates: Experimental Evaluation and Process Modeling
,” Int. J. Mech. Sci.
, 50
(4
), pp. 704
–718
. 30.
Zhang
, Q. F.
, Cai
, Z. Y.
, Zhang
, Y.
, Zhang
, Y.
, and Li
, M. Z.
, 2013
, “Springback Compensation Method for Doubly Curved Plate in Multi-Point Forming
,” Mater. Des.
, 47
, pp. 377
–385
. 31.
Asnafi
, N.
, 2001
, “On Springback of Double-Curved Autobody Panels
,” Int. J. Mech. Sci.
, 43
(1
), pp. 5
–37
. 32.
Lee
, E. H.
, Yang
, D. Y.
, Yoon
, J. W.
, and Yang
, W. H.
, 2015
, “Numerical Modeling and Analysis for Forming Process of Dual-Phase 980 Steel Exposed to Infrared Local Heating
,” Int. J. Solids Struct.
, 75–76
, pp. 211
–224
. 33.
Gisario
, A.
, Barletta
, M.
, Venettacci
, S.
, and Veniali
, F.
, 2015
, “Laser-Assisted Bending of Sharp Angles With Small Fillet Radius on Stainless Steel Sheets: Analysis of Experimental Set-Up and Processing Parameters
,” Lasers Manuf. Mater. Process.
, 2
(2
), pp. 57
–73
. 34.
Liu
, P.
, Zhang
, T. C.
, Guo
, B.
, Yang
, L.
, Shan
, D.
, and Zong
, Y.
, 2019
, “Deformation Path and Springback Behavior in Double-Curved Bending at High Temperature
,” J. Mech. Sci. Technol.
, 33
(9
), pp. 4361
–4370
. 35.
Wang
, A.
, Zhong
, K.
, El Fakir
, O.
, Liu
, J.
, Sun
, C.
, Wang
, L.-L.
, Lin
, J.
, and Dean
, T. A.
, 2017
, “Springback Analysis of AA5754 After Hot Stamping: Experiments and FE Modelling
,” Int. J. Adv. Manuf. Technol.
, 89
(5
), pp. 1339
–1352
. 36.
Saito
, N.
, Fukahori
, M.
, Minote
, T.
, Funakawa
, Y.
, Hisano
, D.
, Hamasaki
, H.
, and Yoshida
, F.
, 2018
, “Elasto-Viscoplastic Behavior of 980 MPa Nano-Precipitation Strengthened Steel Sheet at Elevated Temperatures and Springback in Warm Bending
,” Int. J. Mech. Sci.
, 146–147
, pp. 571
–582
. 37.
Liu
, C.
, Yao
, Y. L.
, and Srinivasan
, V.
, 2004
, “Optimal Process Planning for Laser Forming of Doubly Curved Shapes
,” ASME J. Manuf. Sci. Eng.
, 126
(1
), pp. 1
–9
. 38.
Dang
, X. B.
, He
, K.
, Li
, W.
, Zuo
, Q. Y.
, and Du
, R. X.
, 2019
, “Incremental Bending of Three-Dimensional Free Form Metal Plates Using Minimum Energy Principle and Model-Less Control
,” ASME J. Manuf. Sci. Eng.
, 139
(7
), p. 071009
. 39.
Wei
, B.
, Wei
, Y. N.
, Zhang
, F. F.
, He
, K.
, Dang
, X. B.
, and Du
, R. X.
, 2021
, “Springback Control and Plastic Deformation of Sheet Metals With Large Curvature in Heat-Assisted Incremental Bending Process
,” Int. J. Adv. Manuf. Technol.
, 112
(5–6
), pp. 1483
–1500
. 40.
Zhang
, F. F.
, Zhang
, J.
, Zuo
, Q. Y.
, Dang
, X. B.
, and He
, K.
, 2019
, “Experimental and Numerical Study on Deformation Behavior of Doubly Curved Sheet Metals During Incremental Bending Process
,” Int. J. Adv. Manuf. Technol.
, 104
(5–8
), pp. 2739
–2750
. Copyright © 2022 by ASME
You do not currently have access to this content.
