Research On Surface Quality In Single Point Incremental Sheet Metal Forming

Single point incremental sheet metal forming is a new sheet plastic forming technology,which adopts the method of “Layered Manufacturing”.Compared with the traditional forming methods,single point incremental sheet metal forming has many characteristics,such as no specific die,shorten the processing cycle,high formability,etc.It can develop new product swiftly,economically and in high quality. Therefore, this technology is particularly suited to the development and manufacturing of mall batch,diverse products. It has a wonderful market prospect in aviation, automobile panels and other fields.Single point incremental sheet forming is one non-mold flexible manufacturing technology. Its surface quality is one of the main factors affecting the quality and aesthetic of incremental forming. In this thesis, a finite element analysis of single point incremental sheet metal forming was set up by using ABAQUS.Then massive experimental analysis of the forming process are conducted.Ultimately the parameters of affecting the surface quality of molded molding were optimized to obtain a better surface quality of the molding, the main contents are as follows:(1)On the basis of understanding the principle of the single point incremental sheet metal forming technology,processing parameters(layer spacing,forming angle,forming tool head diameter)which affect the sheet metal forming process were analyzed through theoretical strain.Compared with theoretical and experimental analysis of sheet metal forming process tiered progressive deformation force.Laying a solid foundation for the subsequent further numerical simulation analysis and experimental analysis about the product surface quality.(2)The processes of single point incremental sheet metal forming was analyzed by applying finite element analysis software ABAQUS,including the creation of the process components,define the material model,meshing,contact settings, analysis steps and interaction settings,set the boundary conditions,etc.Then the forming process of changing the forming angle, the tool head diameter and layer spacing is simulated,the equivalent stress of forming processes under different processing parameters was analyzed,and the impact of this results on the surface quality was also analyzed.(3)Using of CNC machining center to build experimental platform, design the experimental fixture,write the forming trajectory,change the three forming parameters of the layer spacing,forming Angle,the tool head diameter to work out different forming parts, analyze the influence of these processing parameters for forming longitudinal surface quality,which is obtained from these measured results of the surface roughness, surface topography and surface texture,and compared with the theoretical analysis to analyze the reason for the differences. By using the orthogonal experiment analysis to make a sequence for the three processing factors of layer spacing, forming angle and tool head diameter based on the influence degree of surface quality, finally put forward the optimization scheme.(4)In addition to these factors of forming angle,the tool head diameter and layer spacing,there are two factors to be analyzed for its impact on surface quality which are spindle speed and feed rate,we can see the influence of these two factors shaping processing lines of "fish-scale pattern",which affects the quality of the lateral surface.There are experimental analysis which change these two processing parameters of feed rate and spindle speed,measured the surface roughness, surface topography and surface "fish-scale pattern" lines to obtain the results of its impact on the quality of the lateral surface of the molding, put forward the optimization advice.