The Force Analysis Of 1060 Aluminum Sheet's Ultrasonic Vibration Of Single Point Incremental Forming

Single point incremental forming is a new type of sheet forming methods.Compared with the traditional stamping,it does not need special mold,being able to form different shapes of parts,shorting the cycle of product,reducing production cost,meeting the rapid development of new products and the personalized needs of small batch production.However,in the process of single point incremental forming,different process conditions and forming force will cause larger changes in the contact stress and strain state.Causing the defects such as rupture,accumulation,wrinkling,the forming quality and precision was reduced.Therefore,study the forming force and the law of influence on the forming quality and efficiency have become a problem urgently to be solved in this forming technology.A kind of ultrasonic vibration single point incremental forming method based oin numerical control technology was put forward by this paper.By changing the mormentary contact state,the lubrication condition and the deformation mechanism of material between tool head and part,the forming force was reduced arnd the forming precision was improved.On the basis of the analysis of the contact between the tool and the material the analytic mathematic models of single point incremental forming force was established.The forming force of the 1060 aluminum plate under different process conditions had been calculated by the model.And the forming mechanism of ultrasonic vibration in the process was analyzed.The finite element analysis model of ultrasonic vibration single point incremental forming was established.The deformation force of the forming process was systematically simulated by the finite element analysis software ABAQUS,obtaining the rule of the influence of different process parameters on the forming farce.The simulation experience formula between the forming force and the feed layer spacing,tool head diameter and vibration amplitude and frequency was established by the multi-factor orthogonal regression analysis method.It can be concluded that the forming force and the change trend have the very good consistency after the comparison between theoretical analysis results and the simulation results.It provided important theoretical basis in depth study of single point incremental forming.The single point incremental forming experiments were done on Hass CNC machine.The ultrasonic vibration spindle and the sheet metal clamping system were designed.The test system of forming force was designed based on Kistler.Through a large number of forming experiments,the law influence of different process parameters and vibration parameters on the forming force were obtained.The experimental results validate the theoretical analysis and simulation analysis.This is a good guide for the future research work.