Directing the Material Flow and Form Filling through a Multi-axis Forming Process

Abstract

Multi-axis forming is a six degree of freedom forming process. This process influences actively the material flow by defining a six dimensional tool motion path and the corresponding tool velocity. Within this process, it is possible to combine a linear forming movement followed by a rolling movement and therefore tailor the induced local material properties of the work piece. The research objective of this work is to observe and quantify the interaction between tool motion and material flow for the purpose of process planning. Experiments are conducted to examine the horizontal material flow within a multi-axis forming process of a plane L-shaped work piece. Three different punches form the material: Flat, cylindrical and cone-shaped. The horizontal material flow is recorded through a transparent die by a camera to measure the material flow for different tool motions. It is shown, that a multi-axis forming process can adjust the local material flow. The resulting redirection of the material flow after the sharp inward facing edge of the L-shape is analyzed and compared. With a smaller active zone compared to a standard linear pressing, the multi-axis forming forces are reduced. In addition, the reservoir with the remaining material is more concentrated. Finally, it is possible to direct the material flow with the punch motion, which can be used to determine local part properties.