FORMING OF SHEET DETAILS WITH CURVILINEAR SIDES WITH ELASTOMER PRESSURE

In the article, the authors present a method of constrained bending of sheet parts with curvilinear sides by the elastic media. They describe the process of constrained bending and the scheme of the experiment. After the first transition, a part with thinning in the radius and high side springing is obtained. The second transition, on a low-height rigging, a wave of excess material is first formed in the radius zone, which settles on the contour of the mandrel with a set of thickness. The stages of forming a semi-finished product are given. The experiment showed the feasibility of constrained bending of curved sides, wall thickness measurements showed that the second transition results in a thickening of the part wall. Finite element modeling of a constrained bend is performed to study the effect of excess of the Board on the thickening in the bending zone. Numerical studies of deformation processes have been carried out. An example of a diagram of the part thickness change for various deformation stages as a result of numerical studies is given. Dependence of part height exceeding with loss of stability during shaping is established. Examples of defects - folds are given.

Microstructure Evolution in Cu–0.5 wt% Zr Alloy Processed by a Novel Severe Plastic Deformation Technique of Rotational Constrained Bending

In the present study, a coarse-grained Cu–0.5 wt% Zr alloy was repeatedly processed by a novel technique of rotational constrained bending (RCB). In this technique, the workpiece was deformed by bending in a channel with an angle of 90°, using a rotating roller. The influence of the number of passes (N) of RCB on strain distribution, microstructure evolution and mechanical properties of the alloy was investigated. The heterogeneous distribution of the microhardness in the billet cross-section after the first pass was transformed into a homogeneous one after twelve passes, due to the rotation of the sample by 90° clockwise between individual passes. In addition, the gradual refinement/homogenization of the microstructure and formation of strong (110) crystallographic texture were found with increasing N. The initial grain size of 180 μm decreased down to 3.4 μm after twelve passes. The dislocation density increased by two orders of magnitude after RCB processing. In accordance with the grain-size refinement and the strong increase of the dislocation density, RCB processing significantly enhanced the strength of the alloy, while the ductility considerably decreased. The yield stress increased from 63 to 524 MPa, while the elongation to failure decreased below 10% after twelve passes.

Analytical model for determining allowances for elastomer constrained bending of aircraft parts

In the article, the authors present a method of constrained bending of aircraft sheet parts with curved sides by an elastic medium. The process of conducting constrained bending is described. A schematic description of the process is presented. The manufacture of a part is carried out in two steps. As a result of the first step, a piece is obtained with thinning in the radius part, the second step is accomplished with a unit die of reduced height. The resulting wave of excess material is deformed along the radius of the bending mandrel. In the finished part, an increase in the thickness of the workpiece is observed in the zone of the bending radius. The wave of excess material is formed due to a special allowance, the size of which is the critical factor for achieving this increase in thickness. The analytical model for determining the allowance is based on generally accepted assumptions and principles for calculating process parameters. To determine the allowance, an approximation of the shape of the excess wave by a tangential function is proposed. This allows you to get an analytical dependence that relates the geometry of the part and the thickening of the wall to the size of the allowance. The size of the allowance is limited to a certain range, the lower boundary of which is determined by the onset of plastic deformations, the upper one - by the possibility of loss of stability, leading to irreparable spoilage. The results are illustrated by graphs of the dependence of the minimum and maximum allowance for the side height on the ratios of the workpiece wall thickness, the radius of the side bending and the radius of the side in plan. Characteristic curves and analytical dependencies are presented in a dimensionless form, where the geometric parameters are assigned to the radius of the bending tool, that is, to the radius of bending of the part side on the inner surface.

Numerical Investigation on Strain Properties of Ti6Al4V Alloy Processed by Constrained Bending and Straightening Severe Plastic Deformation

This paper presents a numerical investigation on strain properties of Ti6Al4V alloy processed by constrained bending and straightening (CBS) severe plastic deformation (SPD) technique. CBS is a new SPD method that has been proposed to enhance continuous processing of metal sheets and improve magnitude and homogeneity of induced properties such as strain. The model considers a rectangular sheet of Ti6Al4V alloy processed with CBS at 2, 4 passes denoted as N2, N4 each combined with 10, 5, 3 mm feed length denoted as F10, F5, F3 respectively. ABAQUS Standard FEA Software was used to simulate and investigate the magnitude and homogeneity of equivalent plastic (EP) strain induced in material. Results show that for all feeds, magnitude values of EP strain at N4 passes were higher than those at N2 passes. The magnitude of EP strain increased with the number of passes. Values of both magnitude and homogeneity of EP strain were highest at F3 feed followed by those at F5 and F10 feeds respectively. The study has promised that CBS is the potential process for continuous production of metal sheets with improved EP strain magnitude and homogeneity.