Abstract
In a modern production environment, flexible manufacturing methods are important because an overall trend towards mass customization and on-demand production is observed. Kinematic and incremental forming methods with generic tools can provide a large product variation but a deeper understanding of the forming mechanisms is required for process modelling, e.g. Incremental Swivel Bending (ISB). Particularly crucial is to identify the influences on the forming zone in order to purposefully control the material flow of a forming process. For a bending process where the bending moment is transmitted by clamping tools, this paper presents a method to alter the contact pressure distribution in order to affect the angular size and strain gradient of the forming zone. In the light of these results, the presented method can be deployed for a tooling with adaptive contact pressure to directly influence material flow, in particular using generic tools to overall provide a better control of flexible forming methods.
Highlights
Since mass personalization is a driving force within industry 4.0, conflicts arise between customer on demand diversification and mass production [1]
From the numerical simulations of the segmented tooling, the forming zone angles as well as longitudinal strain maxima are evaluated over bending angle
Our study investigates the influence of the forming zone of force-fitted bending by varying the contact pressure distribution within the clamping area
Summary
Since mass personalization is a driving force within industry 4.0, conflicts arise between customer on demand diversification and mass production [1] To solve this conflict, agile, flexible and smart production systems are required for manufacturing technologies [2,3]. Forming processes with geometry-specific tools (e.g. deep-drawing) are limited regarding achievable variety of part geometries with a distinct tooling. To maintain their advantage of high dimensional accuracy of produced parts, the ability to form small radii and a good process reliability on the one hand and, on the other hand, to overcome the disadvantage of inflexibility, is an ongoing research challenge. Multi point forming approaches arise, where the die consists of discrete actuatoric punches, which enable a great shape variation [6,7,8,9]
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