Flexible Metal Forming Technologies: Principles, Process and Equipment

Description

This book systematically introduces the principles of flexible forming technologies to manufacture thin-walled complex-shaped components, the mechanism of controlling the material flow, the design and the configuration of flexible forming technologies’ equipment and tools. It covers new technologies and new processes for forming hollow components, and relevant research on forming mechanisms, deformation laws, and defect control with examples from practical applications. It will be a useful reference for researchers, engineers, graduate and undergraduate students in aerospace, nuclear, railway, vehicle and petrochemical engineering, etc. Preface Acknowledgments Contents About the Editor 1 Introduction and State of the Art of Flexible Forming Technologies 1.1 Introduction 1.2 Flexible Forming Processes, Equipment, Tools and Controls 1.2.1 Flexible Forming Process 1.2.2 Flexible Forming Equipment and Tools 1.2.3 Flexible Forming Control 1.3 Materials for Flexible Forming 1.3.1 Flexible Forming Material Type 1.3.2 Flexible Forming Material Structure 1.4 Tribology in Flexible Forming 1.5 Flexible Forming Processes Simulation 1.6 Development and Future Trends for Flexible Forming Technologies 1.7 Conclusion References 2 Flexible Incremental Sheet Metal Forming Technology 2.1 Introduction 2.2 Principles of Flexible, Incremental Forming Technology 2.2.1 Principle of Single Point Incremental Forming 2.2.2 Principle of Two Points Incremental Forming 2.2.3 Principle of Double-Side Incremental Forming 2.2.4 Principle of Multi-stage Incremental Forming 2.3 Systems, Tools and Path Control 2.3.1 The System of the ISF Equipment 2.3.2 Forming Tools and Path Control of the ISF System 2.4 Deformation Mechanism of Flexible Incremental Forming 2.4.1 Flexible Incremental Forming Material Flow Law 2.4.2 Theoretical Analysis of Typical Areas of Flexible Incremental Forming 2.5 Warm Incremental Forming of 2060 Al-Li Alloy Sheet [28] 2.5.1 The Principle and Equipment Development of Warm Incremental Forming of 2060 Al-Li Alloy Sheet 2.5.2 FEM of Warm Incremental Forming of 2060 Al-Li Alloy 2.5.3 Experimental Study on Warm Incremental Forming of 2060 Al-Li Alloy Sheet 2.6 Hot Incremental Forming of TC4 Sheet [29] 2.6.1 Principle of Hot Incremental Forming of TC4 Sheet 2.6.2 FEM of Hot Incremental Forming of TC4 Sheet 2.6.3 Experimental Study on Hot Incremental Forming of TC4 sheet References 3 Flexible Spinning Forming Technology 3.1 Introduction 3.2 Principles and Flow Mechanism of Flexible Spinning Forming 3.3 Equipment Configuration of Spinning Forming 3.3.1 Equipment Configuration of the Horizontal Spinning Machine 3.3.2 Equipment Configuration of the Vertical Spinning Machine 3.4 Spinning Forming Tools Design and Path Planning 3.4.1 Spinning Tooling Design 3.4.2 Spinning Path Design 3.5 Thin-Wall and Revolving Body Components of Spinning Forming 3.5.1 Research Status 3.5.2 Technical Principle 3.5.3 Finite Element Analysis 3.5.4 Analysis of Experimental Results 3.6 Bimetallic Composite Tube of Spinning Forming 3.6.1 Research Status 3.6.2 Technical Principle 3.6.3 Finite Element Analysis 3.6.4 Analysis of Experimental Results 3.7 Power Spinning of Thin-Walled Components 3.7.1 Research Status 3.7.2 Technical Principle 3.7.3 Finite Element Analysis 3.7.4 Analysis of Experimental Results References 4 Flexible Multi-point Plate Metal Forming Technology 4.1 Introduction 4.2 Principles of Flexible Multi-point Forming 4.3 Shape Adjusting and Die Design of Multi-point Die 4.3.1 Shape Adjusting 4.3.2 Die Design of Multi-point Die 4.4 Process Simulation of Flexible Multi-point Forming 4.5 Typical Complex Surface Components Forming 4.5.1 Multi-point Forming of Cylindrical Components 4.5.2 Multi-point Forming of Spherical Components 4.5.3 Multi-point Forming of Saddle Surface Components 4.5.4 Multi-point Forming Experiment 4.6 Hybrid Forming Process 4.6.1 Multi-point Rubber Forming 4.6.2 FEM of Multi-point Rubber Forming 4.6.3 Multi-point Rubber Forming Experiment References 5 Flexible 3D Profile Roll Forming Technology 5.1 Introduction 5.1.1 Concept of Roll Forming 5.1.2 The Development and the State-Of-Art of FRF Equipment 5.2 Principles of 3D Flexible Roll Forming Systems 5.2.1 Key Technologies of Flexible Roll Forming 5.2.2 Flexible Roll Forming Realization 5.3 Forming Process Analysis and Design Rules of Roll 5.3.1 Forming Process Analysis 5.3.2 Design Rules 5.4 Materials Flow and Forming Defects 5.4.1 Materials Flow 5.4.2 Forming Defects 5.5 Forming Simulation and Shape Control 5.5.1 Forming Simulation 5.5.2 Shape Control 5.6 Summary and Outlook References 6 Tube 3D Quench Forming Technology 6.1 Introduction 6.2 Principles of Tube 3D Quench Forming Technology 6.2.1 Principle of Tube 3D Quench Forming Based on a Single-Arm Robot 6.2.2 Principle of Tube 3D Quench Forming Based on a Double-Arm Robot 6.2.3 Principle of Tube 3D Quench Forming Based on a Parallel Robot 6.2.4 Principle of Tube 3D Quench Forming Based on Movable Roller-Die 6.3 System and Key Tools of Tube 3D Quench Forming 6.4 Forming Path Plan of Robot 6.4.1 Robot Kinematics Model 6.4.2 Forming Path Plan of a Clamping Device 6.4.3 Forming Path Plan of Movable Roller-Die 6.5 Deformation Mechanism of Tube 3D Quench Forming 6.5.1 Mechanical Property Test of Steel Tube 6.5.2 Establishment of 3DQ Finite Element Model 6.5.3 Temperature Distribution of Induction Heating 6.5.4 3DQ Forming Simulation Based on a Robot Arm 6.5.5 3DQ Forming Simulation Based on Roller Structure 6.6 Microstructure and Shape Control 6.6.1 Tube 3D Quench Forming Based on a Single-Arm Robot 6.6.2 Tube 3D Quench Forming Based on Movable Roller-Die 6.6.3 Microstructure and Property Analysis of Components References 7 Tube 3D Free Bending Forming Technology 7.1 Introduction 7.2 Principles of Tube 3D-FEB Technology 7.2.1 Principle of Three-Axis FBF System 7.2.2 Principle of Five-Axis and Six-Axis FBF System 7.2.3 Principle of the FBF System Based on the Parallel Mechanism 7.2.4 Principle of FBF Based on the Multi-rollers Structure 7.3 System, Die and Tools Design of the 3D-FBFT Equipment 7.3.1 Software and System Design of the 3D-FBFT Equipment 7.3.2 Bending Die and Tools Design of the Tube Free Bending System 7.3.3 Bending Die and Guider Design of the Profile Six-Axis Free Bending Equipment 7.4 U-R Theoretical Model and Relationship 7.4.1 Calculation of the Transition Section Length 7.4.2 Derivation of U-R Relationship 7.5 Trajectory Control of Bending Die 7.5.1 Mechanism of Controlling the Movement Trajectory of Bending Die 7.5.2 Mechanism of FBF of Hollow Spiral Components 7.5.3 Mechanism of FBF of Involute Hollow Components 7.5.4 Mechanism of Six-Axis Free Bending Forming of Profile Member Components 7.6 3D-FBFT Analysis and Process Simulation 7.6.1 Process Analysis of 3D-FBFT 7.6.2 Theoretical Analysis of the 3D-FBFT 7.6.3 Finite Element Simulation of the 3D-FBFT 7.7 Hot Free Bending of Titanium Alloy Tube 7.7.1 Research Status of Thermal Bending 7.7.2 The Principle of Hot 3D-FBF Technology 7.7.3 Finite Element Analysis of the 3D-FBF Process of Titanium Alloy Tubes 7.7.4 Experimental Study on Hot 3D-FBF of Titanium Alloy Tubes References 8 Flexible Tube Rolling Bending 8.1 Introduction 8.2 Process Principle of Flexible Roll Forming 8.2.1 Principle of the Plane Roll Forming System 8.2.2 Principles of Three-Dimensional Roll Forming 8.2.3 Theoretical Analysis of Roll Forming 8.3 Flexible Roll Bending System and Roller Structure Design 8.3.1 Function of the Flexible Roll Bending System 8.3.2 Design of Flexible Roll Bending Roller Structure 8.4 Analysis of Forming Process of Flexible Roll-Bending System 8.4.1 Process Analysis Process 8.4.2 Analysis of the Geometric Relationship of the Forming Process 8.5 Finite Element Simulation Analysis of Flexible Roll-Bending System Forming 8.5.1 Finite Element Simulation of Rectangular Tube Plane Roll Bending 8.5.2 Finite Element Simulation of Plane Roll-Bending of Complex Cross-Section Profiles 8.5.3 Three-Dimensional Finite Element Simulation of Square Tube Rolling References 9 Flexible Tube Die-Less Forming 9.1 Introduction 9.2 Principles of Tube Die-Less Forming 9.2.1 Principle of Die-Less Forming of Complex Section Tube with Groove Characteristics 9.2.2 Stress Analysis of Multi-pass Incremental Forming 9.2.3 Strain Analysis of Multi-pass Incremental Forming 9.3 Tube Incremental Forming 9.3.1 Analysis of Forming Process 9.3.2 Forming Process Simulation 9.3.3 Forming Process Experiment 9.3.4 Forming Defect Control 9.4 Tube Heating Incremental Forming 9.4.1 Thermal Incremental Forming Experiment 9.4.2 Microstructure Analysis of Incremental Hot Forming 9.5 Tube Induction Heating Bending Process 9.5.1 Principle of Medium Frequency Induction Heating Bending 9.5.2 Finite Element Simulation of Medium Frequency Induction Heating Bending 9.5.3 Experiment of Medium Frequency Induction Heating Bending References