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首页> 外文期刊>Journal of engineering materials and technology >Accommodation of Springback Error in Channel Forming Using Active Binder Force Control: Numerical Simulations and Experiments
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Accommodation of Springback Error in Channel Forming Using Active Binder Force Control: Numerical Simulations and Experiments

机译：主动粘合剂力控制在通道成形中回弹误差的调节：数值模拟和实验

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摘要

Springback in a forming process is due to the elastic deformation of the part during unloading. This manufacturing defect can be accounted for through proper tooling design or through proper design and control of the magnitude and history of restraining force. Using finite element analyses of the process: (1) the effects of restraining force on the springback phenomena when stamping channels from aluminum sheet are investigated; (2) a strategy to control the binder force during the forming operation in order to reduce springback and simultaneously avoid tearing failure is described; and (3) a binder force control strategy which provides robustness in the presence of process parameter uncertainty is implemented. The process history and controller designed using finite element analyses is then experimentally verified: excellent agreement between simulation and experiments is obtained. A binder force history, which leads to a significant reduction in the amount of springback incurred by the formed part without reaching critical stretching conditions, was proposed. Although an optimal forming history was found, in order to ensure that part shape error remained minimized even in the event of variations in processing parameters such as friction, a closed-loop control algorithm was developed whereby the binder force is altered during the process in order to provide a robust, repeatable stretching history. Experiments were performed using a double-action servo-controlled process and were found to produce the desired results demonstrating both the accuracy of the numerical simulation and the success of the proposed active-binder force control method to obtain net shape.
机译：成型过程中的回弹归因于零件在卸载过程中的弹性变形。这种制造缺陷可以通过适当的工具设计或通过适当设计和控制约束力的大小和历史来解决。使用该过程的有限元分析：（1）研究了从铝板冲压通道时约束力对回弹现象的影响； （2）描述了一种在成形操作过程中控制粘合力以减少回弹并同时避免撕裂破坏的策略； （3）实施了一种在过程参数不确定的情况下提供鲁棒性的结合力控制策略。然后通过实验验证了使用有限元分析设计的过程历史和控制器：在仿真和实验之间取得了极好的一致性。提出了结合力历史，其导致在不达到临界拉伸条件的情况下由成型部件引起的回弹量显着减少。尽管找到了最佳的成型历史，但为了确保即使在加工参数（例如摩擦力）发生变化的情况下，零件形状误差也保持最小，开发了一种闭环控制算法，从而在加工过程中按顺序改变了粘结力提供强大，可重复的拉伸历史。实验是使用双作用伺服控制过程进行的，发现产生了预期的结果，证明了数值模拟的准确性以及所提出的主动粘结剂力控制方法获得网状形状的成功。

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