Mould correction for sheet-metal multi-step incremental air-bending forming based on close-loop control and FEM simulation |
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Authors: | Zemin Fu Jianhua Mo Pan Gong Wenxian Zhang Zhongwei Li Kui Huang |
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Affiliation: | aState Key Laboratory of Material Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, Hubei, PR China;bTsinghua University, Beijing, PR China;cMechanical department, Xiamen University of Technology, Xiamen 361021, Fujian, PR China |
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Abstract: | There exist errors between the manufactured workpieces and the CAD models due to the springback of sheet-metal incremental air-bending forming. To reduce these errors, an off-line closed-loop control iterative algorithm, combined by fast Fourier and wavelet transform, is developed from the displacement adjustment method (DAM), smooth displacement adjustment method (SDAM) and deformation transfer function method (DTFM) for die surface. With this algorithm, the mould surface of sheet-metal incremental air-bending forming could be properly corrected, and the springback errors of the formed workpieces could be effectively reduced. In order to reduce mould cost and labor cost, the springback tests of workpieces forming, needed in the iterative process of closed-loop control system, are substituted by finite element model (FEM) simulation. The above correction algorithm was used in a semiellipse-shape workpiece incremental air-bending forming. Its average errors are +0.74/−0.39 mm. The results show that the mould correction algorithm with Fourier and wavelet transform is reasonable and the means of FEM simulation are effective. It can be taken as a new approach for sheet-metal multi-step incremental air-bending forming and mould design. |
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Keywords: | Sheet-metal incremental air-bending forming Mould correction Close-loop control Wavelet transform Fourier transform FEM simulation |
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