Abstract
With the increasing demand for parts with large sizes and complex cross-sectional shapes, the required target shapes are increasingly difficult to meet. In this paper, a flexible 3D stretch bending device has been developed, which can form complex cross-sectional 3D parts with 2 degrees of freedom at one time and can form large sizes 3D parts. Compared with traditional monolithic molds, discrete molds using in flexible 3D stretch bending forming are more convenient for shape adjustment of target profile. The multi-point roller dies are composed of multiple different roller-type die units. In order to better evaluate the forming accuracy of 3D parts, the influence of the number, shape, and surface of the roller dies on the forming results is discussed. The influence of different parameters on the forming accuracy is studied by numerical simulation, and the results are compared with the experimental results. From the perspective of forming accuracy, the influence of FSBR process and different parameters on the forming result is analyzed. Analysis of the dimple and shape errors of the FSBR parts shows that the number, shape, and surface of RDU directly affect the forming accuracy. By modifying the die parameters, the surface dimples can be reduced and the forming accuracy can be improved.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Gu ZW, Lei J, Xin L, Li JZ, Ge Y (2019) Stretch bending defect control of L-section SUS301L stainless-steel components with variable contour curvatures. J Iron Steel Res Int 26(1):1376–1384
Zhao J, Zhai RX, Qian ZP, Ma R (2013) A study on springback of profile plane stretch–bending in the loading method of pretension and moment. Int J Mech Sci 75(Complete):45–54
Clausen AH, Hopperstad OS, Langseth M (2001) Sensitivity of model parameters in stretch bending of aluminium extrusions. Int J Mech Sci 43(2):427–453
Miller JE, Kyriakides S, Bastard AH (2001) On bend-stretch forming of aluminum extruded tubes - I: experiments. Int J Mech Sci 43(5):1283–1317
Miller JE, Kyriakides S, Corona E (2001) On bend-stretch forming of aluminum extruded tubes - II: analysis. Int J Mech Sci 43(5):1319–1338
Corona E (2004) A simple analysis for bend-stretch forming of aluminum extrusions. Int J Mech Sci 46(3):433–448
Gantner P, Bauer H, Harrison DK, Silva AKMD (2005) Free-bending—a new bending technique in the hydroforming process chain. J Mater Process Technol 167(2–3):302–308
Chatti S, Hermes M, Tekkaya AE, Kleiner M (2010) The new TSS bending process: 3D bending of profiles with arbitrary cross-sections. CIRP Ann Manuf Technol 59(1):315–318
Cai ZY, Li MZ (2002) Multi-point forming of 3D sheet metal and the control of the forming process. Int J Press Vessel Pip 79(4):289–296
Wang XT, Li MZ (2020) Research on three-dimensional curved surface rolling based on rigid arc-shaped rollers. Int J Adv Manuf Technol 107(1–2):805–814
Wang SH, Cai ZY, Li MZ (2010) Numerical investigation of the influence of punch element in multi-point stretch forming process. Int J Adv Manuf Technol 49(5–8):475–483
Li Y, Li MZ (2019) Effect of incremental multi-step technology on longitude bending of 3D curved part in continuous roll process. Int J Adv Manuf Technol 105(1–4):1777–1789
Wang SH, Cai ZY, Li MZ, Lan YW (2012) Numerical simulation on the local stress and local deformation in multi-point stretch forming process. Int J Adv Manuf Technol 60(9–12):901–911
Cai ZY, Li MZ, Lan YW (2012) Three-dimensional sheet metal continuous forming process based on flexible roll bending: principle nand experiments. J Mater Process Technol 212:120–127
Cai ZY, Wang SH, Xu XD, Li MZ (2009) Numerical simulation for the multi-point stretch forming process of sheet metal. J Mater Process Technol 209(1):396–407
Li Y, Shi Z, Rong Q, Zhou W, Lin J (2019) Effect of pin arrangement on formed shape with sparse multi-point flexible tool for creep age forming. Int J Mach Tool Manu 140:48–61
Qu EH, Li MZ, Li R, Cui MY, Lin JL (2018) Research on formability in multi-point forming with different elastic pads. Int J Adv Manuf Technol 98:1887–1901
Gao S, Liang JC, Li Y, Hao ZP, Li QH, Fan YH, Sun YL (2018) Precision forming of the 3D curved structure parts in flexible multipoints 3D stretch-bending process. Int J Adv Manuf Technol 95:1205–1213
Liang JC, Gao S, Teng F, Yu PZ, Song XJ (2014) Flexible 3D stretch-bending technology for aluminum profile. Int J Adv Manuf Technol 71:1939–1947
Liang JC, Chen CD, Li Y, Liang C (2020) Effect of roller dies on springback law of profile for flexible 3D multi-point stretch bending. Int J Adv Manuf Technol 108:3765–3777
Jia BB, Wang WW (2018) Shape accuracy analysis of multi-point forming process for sheet metal under normal full constrained conditions. Int J Mater Form 11:491–501
Abebe M, Yoon J, Kang B (2020) Multi-objective six-sigma approach for robust optimization of multi-point dieless forming process. Int J Adv Manuf Technol 21(10):1791–1806
Funding
This work was financially supported by the Project of Jilin Provincial Scientific and Technological Department (20190302037GX, 20190201110JC); Project of Jilin Provincial Development and Reform Commission (2019C046-2); and the Project of Education Department of Jilin Province (JJKH20180943KL).
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflicts of interest.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Li, Y., Han, X., Liang, J. et al. Effect of multi-point roller dies on the forming accuracy of profile in flexible 3D stretch bending technology. Int J Adv Manuf Technol 112, 897–905 (2021). https://doi.org/10.1007/s00170-020-06336-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-020-06336-0