Analysis and elimination for drum warpage of U-shaped workpiece with super length and large opening of sheet metal

To study the mechanism of workpiece warpage under air-bending forming, a method combined experiment with numerical simulation is proposed in this paper. Based on Hill’s yielding criterion and plane strain condition, 3D ABAQUS finite element models, used to form the semiellipse-shaped workpiece with...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2017, Vol.88 (1-4), p.931-939
Main Authors: Fu, Zemin, Zhao, Zhifan, Xu, Jia, Yu, Xiaolong, Wang, Jiawei, Xiong, Weijie
Format: Article
Language:English
Subjects:
Bending
Brake presses
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Defects
Deformation
Deformation mechanisms
Engineering
Finite element method
Forming
Industrial and Production Engineering
Mathematical models
Mechanical Engineering
Media Management
Metal sheets
Original Article
Plane strain
Springback
Three dimensional models
Warpage
Workpieces
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Summary:To study the mechanism of workpiece warpage under air-bending forming, a method combined experiment with numerical simulation is proposed in this paper. Based on Hill’s yielding criterion and plane strain condition, 3D ABAQUS finite element models, used to form the semiellipse-shaped workpiece with super length and large opening of sheet metal, are established. The multistep incremental air-bending forming and non-uniform springback processes are simulated. It is pointed out that a large bending force and bed deformation of press brake can lead to warpage defect of workpiece. A technique used reverse deflection compensation for bed deformation of press brake, and female die with a large opening is found to eliminate warpage defect of workpiece. Manifested by the experiment for incremental air-bending forming of this workpiece, the proposed method yields satisfactory performance in improving forming accuracy and eliminating warpage defect of a large workpiece.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-016-8834-7