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2022 | Book

Flexible Metal Forming Technologies

Principles, Process and Equipment


About this book

This book systematically introduces the principles of flexible forming technologies to manufacture thin-walled complex-shaped components, the mechanism of controlling the material flow, the design and the configuration of flexible forming technologies’ equipment and tools. It covers new technologies and new processes for forming hollow components, and relevant research on forming mechanisms, deformation laws, and defect control with examples from practical applications. It will be a useful reference for researchers, engineers, graduate and undergraduate students in aerospace, nuclear, railway, vehicle and petrochemical engineering, etc.

Table of Contents

Chapter 1. Introduction and State of the Art of Flexible Forming Technologies
The impact of the development of Industry 4.0 on the manufacturing industry from the perspective of flexible forming is described in this chapter. Faced with the trend of increasing consumer demand for personalized customization in the future, this article introduces the shortcomings of traditional manufacturing and the technical barriers that need to be overcome in the future of the manufacturing industry. According to the structural characteristics of special-shaped curved surfaces and complex hollow tube metal products, the basic working principles and application scenarios of corresponding flexible forming technologies are introduced, and the development of flexible forming technologies such as spinning, three-dimensional free bending forming, and progressive forming in the field of metal product manufacturing is explained. The status quo and the latest research results, based on the development of a new generation of information technology, further summarize the typical characteristics and development trends of flexible forming technology from the aspects of flexible forming equipment, forming technology, material system, and motion control, and further summarize the “intelligent flexible The basic operation mode of “manufacturing plant” was discussed.
Xunzhong Guo, Cheng Cheng, Hao Zhang, Chunmei Liu, Yong Sun, Albert Sedlmaier, Jie Tao, Yizhou Shen, Hui Wang, Huaguan Li, Ali Abd El-Aty
Chapter 2. Flexible Incremental Sheet Metal Forming Technology
Incremental sheet metal forming (ISF) is a new technology for flexible process that has sprung up in the world used in metal sheet manufacturing. In fact, this is one kind of point press process, using the theory of “layered manufacturing”. This process can produce a large forming limit and complex shape sheet metal with pre-programmed control point by point by numerical control equipment without special mold or by simple mold. This chapters introduces the forming principle of ISF and the different variants. Then the research progress of the ISF technology and the equipment of ISF are also introduced in detail. Finally, based on the principle and deformation mechanism of ISF, the key forming process at different temperatures and different materials are investigated by using the combination of numerical simulation and experiment.
Hui Wang, Shuo Zheng, Haoran Luo, Gui Wei, Xunzhong Guo, Ali Abd El-Aty, Yanbo Gu, Kaihui Guang
Chapter 3. Flexible Spinning Forming Technology
As an advanced technology of metal plastic forming, flexible spinning forming technology has become the core processing method of small batch and multi variety symmetrical and asymmetric rotating hollow thin-walled parts. At present, it has been widely used in the field of metal precision processing, such as aerospace, military industry, nuclear energy, shipbuilding and so on. Based on the basic principle of spinning, the forming processes of thin-walled and revolving body components of spinning forming, bimetallic composite tube of spinning forming and power spinning of thin-walled components are studied by using the combination of numerical simulation and experiment, and finally the spinning parts with excellent forming quality are obtained.
Yizhou Shen, Chunmei Liu, Zijie Wang, Jie Tao, Shixuan Liu, Qiwei Yuan, Bo Li, Jianhua Wang
Chapter 4. Flexible Multi-point Plate Metal Forming Technology
As a New Flexible Plate Metal Forming Technology, Multi-Point Forming Technology Discretizes the Overall Surface of the Traditional Die Into a Series of Highly Controllable and Regularly Arranged Punch Matrix. Each Punch Is an Independent Moving Unit. The Shape of the Forming Surface Is Changed By Controlling the Relative Vertical Height of Each Punch, The Envelope Surface Formed By the Punch Matrix Is the Required Forming Surface, Which Can Quickly Form Various Curved Plates With Different Complex Shapes Without Replacing the Die. Compared With the Traditional Integral Die Forming, It Has the Characteristics and Advantages of High Flexibility, Strong Adaptability and Optimization of Forming Path. It Has Been Successfully Applied in Many Fields, Including High-Speed Train Head Coverings, Automobile Coverings, Ship Exterior Panels, Building Exterior Panels, and Human Skull Repair Etc.
Ali Abd El-Aty, Zushu Huang, Zhenbiao Sun, Chunmei Liu, Wenfeng Guo, Yangyang Deng, Xunzhong Guo
Chapter 5. Flexible 3D Profile Roll Forming Technology
Nowadays, roll forming becomes one of the most promising sheet metal forming method due to its excellent superiority of capital saving and capability of lightweight, high accuracy manufacturing technique. It has been increasingly used in a wide range of sectors, such as aerospace, automotive, transportation, construction, etc. However, with the requirements of rapid manufacturing and more complex customized profile shape in forming direction, such as variable shape, depth, etc., traditional roll forming is no longer suitable due to the movement restrictions along transverse and vertical directions. Also, with the trend of industry 4.0, traditional roll forming is fundamentally lack of machine learning capability for intelligent manufacturing upgrade. A new replacement called (3D) flexible roll forming has been proposed in recent years to confront the above challenges. The technology is carried out via an advanced control system. It is a complicated flexible manufacturing system composed of many key elements/parts, such as six-axis robot arms, high, blankholder system, smart sensors and other key elements.
Yong Sun, Albert Sedlmaier, Qiuquan Guo, Dongxing Zhang, Hui Xia, Shiyi Cu, Jie Dong, Yinwang Ren
Chapter 6. Tube 3D Quench Forming Technology
As an innovative technology, 3DQ can realize the overall flexible forming of ultra-high strength auto parts with complex spatial shape, the steel tube can be bent into any desired shape by controlling the motion trajectory of the robot. Based on the basic principle of 3DQ, combining finite element simulation with forming experiment, this chapter studies the 3DQ forming process based on single arm robot and movable rollers respectively, and explores the influence of process parameters such as heating temperature, tube propulsion speed and robot traction speed on the forming quality of bending components. Finally, the bending components with excellent forming quality are obtained.
Huaguan Li, Xunzhong Guo, Cong Wu, Chao Pan, Jiaxin Guo, Rensixu Zhang, Wenfeng Guo
Chapter 7. Tube 3D Free Bending Forming Technology
The 3D free bending forming technology can realize the overall flexible forming of pipes and profiles with complex spatial shapes by constantly changing the spatial posture of the bending die. This chapter classifies the current free bending equipment based on the forming principle of free bending. Then the key technologies of free bending process system, mold structure, “U-R” relationship, forming trajectory analysis and finite element simulation process are introduced in detail. Finally, the characteristics and advantages of hot free bending are analyzed through finite element simulation and experiment.
Cheng Cheng, Qiucheng Yang, Xunzhong Guo, Xueshan Bai, Shenghan Hu, Hao Chen, Cong Wu, Tao Li, Hao Xiong, Ali Abd El-Aty
Chapter 8. Flexible Tube Rolling Bending
The flexible roll forming technology can realize the integral forming of complex two-dimensional and three-dimensional shapes by changing the reduction and rotation speed of each pair of rollers. Based on the forming principles of plane roll bending and three-dimensional roll bending, this chapter respectively introduces the process system, roller design principles, and process analysis process of plane roll bending and three-dimensional roll bending. Finally, through finite element simulations and experiments, the influence of process parameters such as roller spacing, friction coefficient, roller speed, and forming pass on the quality of aluminum alloy square tube plane and three-dimensional roll-bending is studied respectively.
Chunmei Liu, Qiucheng Yang, Xiaohong Zheng, Haoqi Ni, Gui Wei, Qikang Zhao, Xunzhong Guo
Chapter 9. Flexible Tube Die-Less Forming
Tube die-less forming technology benefits from its characteristics of reducing die processing and material consumption. It is a flexible forming technology in line with today's world outlook on development and will be popularized in aerospace, nuclear energy, petrochemical and other fields. This chapter first introduces the principle of tube die-less forming. It then expounds the die-less forming process of complex section tube fittings with groove characteristics, bellows and large-diameter thick wall guide tube details to guide the processing of these three kinds of parts and other metal tube fittings.
Jie Tao, Shenghan Hu, Xunzhong Guo, Gui Wei, Cheng Wang, Wenjiao Pei, Ali Abd El-Aty
Flexible Metal Forming Technologies
Xunzhong Guo
Copyright Year
Springer Nature Singapore
Electronic ISBN
Print ISBN

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