scholarly journals Research on a Control Strategy of the Symmetrical Four-Roller Bending Process Based on Experiment and Numerical Simulation

Symmetry ◽  
2021 ◽  
Vol 13 (6) ◽  
pp. 940
Author(s):  
Hongqiang Cao ◽  
Gaochao Yu ◽  
Chunfang Yang ◽  
Jun Zhao
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Control Strategy ◽  
Prediction Method ◽  
Quadratic Function ◽  
Curvature Radius ◽  
Monitoring Method ◽  
Physical Experiments ◽  
Roll Bending ◽  
On Line

The intelligent production of sheet metal is a comprehensive technology involving control science, computer science, and sheet metal production. Intelligent rolling is an important development in the production process of sheet metal. In this paper, a new symmetrical four-roller bending (SFRB) process is introduced, which consists of feeding, pre-bending, reverse roll bending, second bending, and forward roll bending and unloading. A control strategy is proposed for the process, including on-line monitoring of curvature, on-line identification of the springback law, on-line prediction of final reduction, and control strategy. A convenient and reliable on-line curvature monitoring method is proposed. The quantitative relationship between the reduction and the curvature, in the form of a quadratic function, was established by physical experiments and numerical simulation, and the online identification of the springback law was realized. An on-line prediction method of the final reduction is proposed, and the determination principle of the reduction of three pre-bending processes is given. Finally, the control strategy of the SFRB process was verified by physical experiments. The relative error of the curvature radius of the final formed parts can be controlled within 0.8%. This research provides new insights into intelligent rolling.

Numerical Simulation of Multiple-Step Incremental Roll-Bending Forming of a Large Metal Sheet to U-Shape

2013 ◽  
Vol 762 ◽  
pp. 627-632
Author(s):  
Da Chao Hu ◽  
Guo Qing Li ◽  
Ze Min Fu
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Large Scale ◽  
Metal Sheet ◽  
Curvature Radius ◽  
Work Piece ◽  
Roll Bending ◽  
Multiple Step

Simulation of multiple-step incremental roll-bending forming and springback of large-scale sheet metal with U shape was implemented in this paper using ABAQUS. In view of the semi-ellipse shape of work piece, a geometric plan using fives arcs with different radius to approach the original shape in piecewise is proposed. On the basis of the programming, reasonable arrange the rolling steps, adjust the parameters in ABAQUS. The largest error of curvature radius of different arcs is less than 5% after simulation of the sheet metal forming according to optimized process fitting with Origin8.0. The results show that the incremental roll-bending method forming the semi-ellipse shape work piece is feasible.

Analytical modeling and numerical simulation for three-roll bending forming of sheet metal

2013 ◽  
Vol 69 (5-8) ◽  
pp. 1639-1647 ◽  
Author(s):  
Zemin Fu ◽  
Xiuli Tian ◽  
Wei Chen ◽  
Bingkun Hu ◽  
Xingyan Yao
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal ◽  
Analytical Modeling ◽  
Roll Bending

scholarly journals Strata behavior and control strategy of backfilling collaborate with caving fully-mechanized mining

2020 ◽  
Vol 12 (1) ◽  
pp. 703-717
Author(s):  
Yin Wei ◽  
Wang Jiaqi ◽  
Bai Xiaomin ◽  
Sun Wenjie ◽  
Zhou Zheyuan
Keyword(s):  
Numerical Simulation ◽  
Control Strategy ◽  
Three Dimensional ◽  
Simulation Method ◽  
Mine Pressure ◽  
Hydraulic Support ◽  
Transition Area ◽  
Pressure Concentration ◽  
Strata Behavior ◽  
And Control

AbstractThis article analyzes the technical difficulties in full-section backfill mining and briefly introduces the technical principle and advantages of backfilling combined with caving fully mechanized mining (BCCFM). To reveal the strata behavior law of the BCCFM workface, this work establishes a three-dimensional numerical model and designs a simulation method by dynamically updating the modulus parameter of the filling body. By the analysis of numerical simulation, the following conclusions about strata behavior of the BCCFM workface were drawn. (1) The strata behavior of the BCCFM workface shows significant nonsymmetrical characteristics, and the pressure in the caving section is higher than that in the backfilling section. φ has the greatest influence on the backfilling section and the least influence on the caving section. C has a significant influence on the range of abutment pressure in the backfilling section. (2) There exits the transition area with strong mine pressure of the BCCFM workface. φ and C have significant effect on the degree of pressure concentration but little effect on the influence range of strong mine pressure in the transition area. (3) Under different conditions, the influence range of strong mine pressure is all less than 6 m. This article puts forward a control strategy of mine pressure in the transition area, which is appropriately improving the strength of the transition hydraulic support within the influence range (6 m) in the transition area according to the pressure concentration coefficient. The field measurement value of Ji15-31010 workface was consistent with numerical simulation, which verifies the reliability of control strategy of the BCCFM workface.

Multi-Step Forward Finite Element Method for the Numerical Simulation of Sheet Metal Forming

2011 ◽  
Vol 474-476 ◽  
pp. 251-254
Author(s):  
Jian Jun Wu ◽  
Wei Liu ◽  
Yu Jing Zhao
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Mapping Method ◽  
Constitutive Relationship ◽  
Element Method

The multi-step forward finite element method is presented for the numerical simulation of multi-step sheet metal forming. The traditional constitutive relationship is modified according to the multi-step forming processes, and double spreading plane based mapping method is used to obtain the initial solutions of the intermediate configurations. To verify the multi-step forward FEM, the two-step simulation of a stepped box deep-drawing part is carried out as it is in the experiment. The comparison with the results of the incremental FEM and test shows that the multi-step forward FEM is efficient for the numerical simulation of multi-step sheet metal forming processes.

Numerical simulation of sheet metal drawing by Maslennikov's technique

2007 ◽  
Vol 187-188 ◽  
pp. 192-196 ◽  
Author(s):  
M. Yamashita ◽  
T. Hattori ◽  
N. Nishimura
Keyword(s):  
Numerical Simulation ◽  
Sheet Metal

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

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