| The sheet metal incremental forming is a kind flexible and dieless forming technologythat recently developed. It can fabricate the sheet pieces from CAD model date quickly andeconomically. This technique has advantages of the low production cost and the shortproduction cycle, so it is adapted for assortments, little bath and short period product. Thesheet metal incremental forming technology is applied in broad field such as aerospace,automobile, shipbuilding, electrical appliances, hardware, etc. In this paper, the simulationstudy for sheet metal5-axis CNC incremental forming has the important practical significanceon the forecast for the confirmation of size, the adjusting extrusion tool posture, the sheetthickness, the forming precision. The main research comments are as follows:First of all, in order to meet the needs of saving materials and reduce forming load, aalgorithm for sheet size intelligent alternative based on STL model was researched in thispaper. The length and width of sheet matal were found out using the smallest rectanglebounding box of bottom boundary polygons. The sheet thickness was determined according tothe plate thickness thinning algorithm and the color cloud picture of sheet thicknessdistribution was generated. Secondly, a method of extrusion tool posture adjustment waspresented based on the input related instruction information controlling5-axis tool axis. Thetool points were obtained through STL model offsetting, contour cutting, dissociating STL.The tool points of different position were classified, then normal vector of tool points wereobtained through different weighting algorithms. The adjusting extrusion tool posture wasachieved based on the input related instruction information controlling5-axis tool axis andnormal vector of tool points. At last, the5-axis CNC incremental forming process wassimulated using ANSYS/LS-DYNA finite element software, the influence of extrusiondirection on the forming accuracy was studied, so theoretical foundation was provided for theactual processing of5-axis CNC incremental forming. |
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