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Deformation characteristics and forming force limits of multi-point forming with individually controlled force–displacement

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Abstract

To solve the problem of springback in traditional multi-point forming (MPF), a new multi-point forming process, namely, multi-point forming with individually controlled force–displacement (MPF-ICFD), is proposed. In this manuscript, traditional MPF and MPF-ICFD are compared. Taking the cylindrical surface as the research object, the change in the springback of a plate is analysed by experiments, and the distribution of the strain and wall thickness of the plate is analysed by numerical simulation. Theoretical analysis is used to calculate the forming window for the MPF-ICFD process, and the results from theoretical analysis are verified by experiments and numerical simulation. The results show that the springback of 1060 aluminium alloy and Q295 for MPF-ICFD can be decreased by 73.8% and 45.5%, respectively, compared with traditional MPF. In traditional MPF, the strain uniformity of the plate is poor, and the maximum thinning rate is 4.5%. For MPF-ICFD, the strain is relatively uniform, and the maximum thinning rate is 0.25%. For an aluminium alloy sheet with a wall thickness of 1.5–3 mm, the upper and lower limits of the forming force for a single head are observed to change linearly from 6.3 to 12.6 kN and from 0.5 to 1 kN, respectively.

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Data availability

The datasets used or analysed during the current study are available from the corresponding author on reasonable request.

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Funding

This work was supported by Shandong Provincial Natural Science Foundation (No. ZR2020ME145) and 333 High-level Talent Training Project of Jiangsu province (third level, 2022).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Harbin Institute of Technology, Weihai, 264209, People’s Republic of China

    Bin-Bin Jia, Gang Chen & Wei-Wei Wang

  2. School of Naval Architecture and Ocean Engineering, Jiangsu Maritime Institute, Nanjing, 211170, People’s Republic of China

    Bin-Bin Jia, Yan Shen & Yanxia Gu

  3. School of Material Science and Engineering, Southeast University, Nanjing, 211189, People’s Republic of China

    Yan Shen

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  1. Bin-Bin Jia
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  2. Gang Chen
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  3. Wei-Wei Wang
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Contributions

The main processing experiment, conception and design of the study, and the preparation of the original manuscript were performed by BJ. WW was responsible for reviewing and supervising the final version. GC was responsible for editing and revising the manuscript. Measurement experiments and analysis were completed by YS and YG.

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Correspondence to Gang Chen.

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Jia, BB., Chen, G., Wang, WW. et al. Deformation characteristics and forming force limits of multi-point forming with individually controlled force–displacement. Int J Adv Manuf Technol 123, 1565–1576 (2022). https://doi.org/10.1007/s00170-022-10236-w

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  • DOI: https://doi.org/10.1007/s00170-022-10236-w

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