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Approach Based on Response-Surface Method to Optimize lining of dies Used in 3D Free-Bending Forming Technology

Chinese Journal of Mechanical Engineering 2024年第5期37卷 307-331页

作者： Cheng Cheng Jiaxin Guo Ali Abd El‑Aty Jie Tao Xunzhong Guo College of Material Science and Technology Nanjing University of Aeronautics and AstronauticsNanjing 211100China Avic Taiyuan Aero-Instruments Co. LtdTaiyuan 030000China Department of Mechanical Engineering College of EngineeringAl Kharj Prince Sattam Bin Abdulaziz UniversityAl Kharj 11942Saudi Arabia Mechanical Engineering Department Faculty of EngineeringHelwan UniversityCairo 11795Egypt

In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of the forming die ***,the effects of die-lining structural parameters on the tube quality,and a method to determine the combination of die-lining structural parameters is yet to be *** study aims to propose a new framework that allows one to understand the effects of various die-lining structural parameters on tube quality and to propose the best combination of die-lining structural ***,finite-element modeling is performed to simulate 3D-FBF and examine the effects of individual die-lining structures on the quality of tube *** simulation results show that the deformation-zone length and die gap are positively correlated with the tube-section distortion and wall-thickness variation,whereas it shows an opposite trend with respect to the bending ***,the lining chamfer radius of the bending die and the guide lining chamfer radius minimally affect the tube forming ***,the optimal die-lining structure is obtained using the response-surface *** tube cross-sectional distortion rate reduced from 2.73 to 2.53%after the die lining is ***,the average inner-wall thickness reduced to 1.06 mm,whereas the average outer-wall thickness increased to 0.97 *** paper proposes a method for optimizing the forming-die-lining mechanism and for improving the tube forming quality in 3D-FBF.

关键词： die lining Forming quality Response surface method Cross-sectional distortion Wall thickness

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