Optimization Of Single-point Progressive Forming Process For Multi-pass Aluminum Alloy Sheet

Single-point progressive forming technology is widely used in various industries.It has the characteristics of short product development cycle,low cost and high process flexibility.It is suitable for the processing and production of small batch and custom parts.The technology is in the development stage,and there are some defects.For example,in the process of processing metal sheets,various complicated stresses and strains will be withstood,and excessive sheet thinning,uneven thickness,and even cracking may occur.Aiming at these defects,this paper studies the influence of the processing angle,layer spacing and tool feed speed on the quality of the formed sheet during the multi-pass single-point incremental forming process.Through the numerical simulation plus experimental verification method,the process parameters of the metal sheet are supported by incremental forming,and the process parameter group in the single-point progressive forming process is reasonably selected to solve the excessive thinning or even cracking of the formed parts.And other defects.The material is made of 1060 aluminum alloy sheet.This material has high cost performance,good elongation and tensile strength,high plasticity,corrosion resistance,electrical conductivity and thermal conductivity.It can be used for pressure processing,extension and bending.In this paper,the numerical simulation of the supporting single-point progressive forming process is carried out,and the simulation model with supporting single-point incremental forming is established.The difficulties in the model building include unit selection,material model selection,contact processing and path loading.explore.The reliability of the finite element simulation model is verified by the error analysis between the data obtained by numerical simulation and the experimental processing results.Based on this simulation model,the process parameters and machining trajectory are optimized for the single-point progressive forming.The optimization of the trajectory is mainly to select the number of processing lanes.The three-pass forming design can solve the uneven distribution of the thickness of the formed parts,and can process the parts with the forming angle exceeding the forming limit angle;the optimization of the single parameters is mainly It is reasonable to select the change trend of tool head radius,forming angle,layer spacing and tool head feed speed between passes in the process of multi-pass progressive forming.Finally,the influence of variousprocess parameters on the quality of the formed parts was studied by orthogonal experiment,and the process parameters of a set of multi-pass single-point incremental forming were optimized.The optimized process parameters were verified by experimental processing.The effectiveness of the group obtained straight-walled cylindrical parts with uniform thickness distribution and good forming performance.Finally,the moldless forming method is combined with the mold forming method for path design and planning,and the straight wall cylindrical parts with complex curved surfaces are processed.The feasibility and reliability of the composite processing are also verified by the experimental processing method.Through the numerical simulation and experimental verification method,it is found that the radius of the tool head is 6mm;the trend of the feed rate of each pass is gradually decreasing;the change angle of the machining angle of each pass is gradually increasing;When the pitch change trend is gradually increased,a straight-walled cylindrical member having good quality and uniform wall thickness distribution can be processed.