Improvement of arc burn defect of initial contact loss of electric hot incremental sheet forming

Abstract

Electric hot incremental sheet forming, which is used to form hard-to-form sheet metal, is viewed as the one of rapid prototyping manufacturing technologies. However, the non-uniform stress distribution of forming regions would cause an initial contact loss phenomenon between the tool and the sheet, and an electric arc burn of the part surface is obtained due to the contact loss. In this work, a control method of axial pressure response was proposed to judge the stability of the initial contact between forming the tool and the sheet. A power supply on-off device was designed for electric hot incremental forming, and the calculation model of the initial axial force was established during deformation. Meanwhile, two response pressure values were proposed to control the power supply starting and the current intervention and to ensure the stability of the power supply during the forming process. In addition to this, the axial force and the surface of part were analyzed further in electric hot incremental sheet forming.