Incremental forming method for thin-walled part with irregular deviation

Abstract

The invention discloses an incremental forming method of a thin-walled part with irregular offset, which properly adjusts the initial position of a plate according to the requirement of a target processing shape: 1) if the target processing shape has large offset in the X-axis direction, the position needs to be corrected by finely adjusting the standard coordinate of the X-axis to ensure accurate forming; (2) if large deviation exists in the Y-axis direction, adjustment is carried out by finely adjusting the standard coordinates of the Y axis, so that the needed machining shape is achieved; (3) if deviation exists in the Z-axis direction, the plane angle of the die can be adjusted through a method of raising the lower portion of the die, and therefore the needed machining shape is achieved; the position relation between the die and the workpiece is allowed to be dynamically adjusted in the machining process, so that the forming path can be changed at any time, the shape change requirements of the part in different stages are met, and high-precision machining of the complex formed part is achieved.

Description

Technical Field

[0001] The invention relates to the field of advanced manufacturing technology, and in particular to a progressive forming method for a thin-walled part with irregular offset. Background Art

[0002] Traditional incremental forming processes have the following limitations when processing parts with complex shapes:

[0003] 1. Limitation of forming limit angle: Traditional incremental forming methods often fail to achieve the required accuracy and quality when processing formed parts with larger angles. This is mainly because when the forming angle is large, the material is prone to instability and rupture, resulting in forming failure.

[0004] 2. Difficulty in processing complex shapes: For parts that require multiple shape changes, such as parts with curved surfaces and asymmetric shapes, it is difficult for traditional processes to maintain consistent shape and dimensional accuracy during processing. The fixed and single forming path makes it helpless when faced with complex geometric shapes.

[0005] 3. Difficulty of shape change during processing: Some parts need to change the forming path multiple times during the processing to achieve a specific shape change.

[0006] Therefore, the prior art has defects and needs to be improved. Summary of the invention

[0007] The technical problem to be solved by the present invention is to provide a progressive forming method for thin-walled parts with irregular offsets in response to the shortcomings of the prior art. By introducing offset control measures when positioning the mold, the processing trajectory can be offset from the mold during the forming process, thereby achieving a more complex forming effect.

[0008] The technical solution of the present invention is as follows:

[0009] A method for incrementally forming a thin-walled part having irregular offsets comprises the following steps:

[0010] According to the requirements of the target processing shape, adjust the initial position of the sheet:

[0011] 1) If the target processing shape deviates greatly in the X-axis direction, it is necessary to correct the position by fine-tuning the standard coordinates of the X-axis to ensure accurate forming;

[0012] 2) If there is a large offset in the Y-axis direction, adjust it by fine-tuning the standard coordinates of the Y-axis to achieve the desired processing shape;

[0013] 3) If there is an offset in the Z-axis direction, the plane angle of the mold can be adjusted by raising the bottom of the mold to achieve the desired processing shape;

[0014] The final forming contour can be obtained by further processing according to the adjusted parameters.

[0015] According to the incremental forming method of thin-walled parts with irregular offsets, for the spherical mold, adjustments are made according to the following formula: z = 0.000015x^3+0.000426yx^2-0.0657tx+500yt; wherein z is the difference between the formed part and the mold height, x is the x-axis offset distance, y is the horizontal offset angle, and t is the tool offset distance percentage.

[0016] According to the incremental forming method of the thin-walled part with irregular offset, before adjusting the initial position of the sheet material, the following steps are also included:

[0017] Step 1: Use CAD / CAM software to create a detailed 3D model of the target mold. After completing the 3D modeling, use the software to generate the corresponding NC code;

[0018] Step 2: After the initial processing of the mold, install it on the progressive forming machine for precise positioning;

[0019] Step 3: After completing the standard positioning of the mold, place the sheet to be processed in the forming area and ensure that the sheet is in uniform contact with the mold.

[0020] By introducing a controlled offset in the die positioning, the trajectory of the standard incremental forming die is changed, so that more complex shapes can be produced. This controlled offset can be adjusted dynamically, so that the needs of large angles and shape changes can be accommodated during the forming process. Compared with traditional incremental forming methods, the present invention overcomes the limitations of traditional technology in manufacturing complex shapes, especially for parts with large angles or that require shape changes during the forming process.

[0021] The beneficial effects of the present invention are embodied in the following aspects:

[0022] 1. Controlled offset of die positioning: By changing the positioning of the die, deviation from the standard trajectory is achieved, making the forming path more flexible and able to adapt to the needs of complex shapes.

[0023] 2. Dynamically adjust the offset: During the forming process, the offset can be dynamically adjusted as needed to ensure that the forming trajectory can effectively adapt to changes in material shape.

[0024] 3. Ability to form complex shapes: The method of the present invention can effectively handle forming tasks with large angles and shapes that require changes, which are difficult to handle with traditional incremental forming methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1is a schematic diagram of the structure to be formed;

[0026] 1. Target processing section profile; 2. Theoretical mold profile; DETAILED DESCRIPTION

[0027] The present invention is described in detail below in conjunction with specific embodiments.

[0028] refer to Figure 1 , Figure 1 It is a progressive forming part with a tilted head. The traditional process cannot complete the processing of special-shaped parts, and it is also impossible to manufacture parts with large forming limit angles. By changing the positioning of the progressive forming, the effect shown in the figure can be achieved.

[0029] Step 1: Use CAD / CAM software to create a detailed 3D model of the target mold. After completing the 3D modeling, use the software to generate the corresponding NC code.

[0030] Step 2: After the initial processing of the mold, it is installed on the incremental forming machine for precise positioning. During the installation process, precision positioning tools such as positioning pins or clamps are required to ensure that the mold is fixed firmly on the machine and accurately aligned to the specified positioning point. The accuracy of this process will directly affect the accuracy of subsequent processing and the quality of the finished product.

[0031] Step 3: After completing the standard positioning of the mold, place the sheet to be processed in the forming area and ensure that the sheet is in uniform contact with the mold. According to the requirements of the target processing shape, adjust the initial position of the sheet appropriately:

[0032] 1. If the target processing shape is greatly offset in the X-axis direction, it is necessary to correct the position by fine-tuning the standard coordinates of the X-axis to ensure accurate forming.

[0033] 2. If there is a large offset in the Y-axis direction, adjust it by fine-tuning the standard coordinates of the Y-axis to achieve the desired processing shape.

[0034] 3. If there is an offset in the Z-axis direction, the plane angle of the mold can be adjusted by raising the bottom of the mold to achieve the desired processing shape.

[0035] Furthermore, for spherical molds, the following formula can be used for adjustment: z = 0.000015x^3 +

[0036] 0.000426yx^2-0.0657tx+500yt, where z is the height difference between the formed part and the mold (that is, the height difference between the standard mold and the processing distance at every moment), x is the x-axis offset distance, y is the horizontal offset angle (the essence of raising the height is to make the processing plane tilt horizontally, and y is the angle of horizontal transformation), and t is the percentage of tool offset distance (the ratio of a certain coordinate offset to the total length of the part in the current direction).

[0037] The final contour can be obtained by processing according to the adjusted parameters. If you want to form other styles of parts, you can change other values ​​to achieve the target requirements.

[0038] Step 4: After ensuring that all positioning and sheet adjustments are completed, enter the adjusted NC code into the incremental forming machine and execute the program. When executing the program, the entire processing process needs to be monitored to ensure that the machine tool operates correctly according to the expected path and process parameters to avoid forming errors caused by incorrect parameters.

[0039] Step 5: During the sheet metal processing, the height of the formed part needs to be measured in real time to ensure that it gradually approaches the target height. For specific measurements, precise measuring tools such as digital calipers or height gauges can be used to record the processing height of each step. If the measured data shows that the height deviates from the expected standard, the machine needs to be stopped immediately and the processing parameters adjusted. As long as the height of the formed part reaches the pre-set target standard, the processing can be stopped.

[0040] Step 6: After processing is completed, carefully remove the formed part from the progressive forming machine. Avoid excessive force during the removal process to avoid damaging the formed part. After the formed part is removed, it is subjected to a final inspection to confirm that its size and shape fully meet the design requirements. If necessary, further post-processing such as deburring and surface treatment can be performed to ensure that the quality and performance of the finished product meet the application standards.

[0041] Formed as attached Figure 1 The progressively formed part with a tilted head shown in the figure has a standard mold with a radius of 70mm, a height of 60mm, and a tool head diameter of 8mm. Based on standard positioning, the feed speed is set to 3000r / min, and the tool setting parameters are offset by 0.5mm in the positive direction of the x-axis (adjusting the x offset will cause the highest point of the part to be offset in the x direction, and adjusting the y offset will cause the highest point of the part to be offset in the y direction), and the left side of the mold is raised by 1mm (the essence of the raising is to make the processing plane tilt horizontally).

[0042] It should be understood that those skilled in the art can make improvements or changes based on the above description, and all these improvements and changes should fall within the scope of protection of the appended claims of the present invention.

Claims

1. A method for incrementally forming a thin-walled part with irregular offset, characterized in that: The following steps are involved: According to the requirements of the target processing shape, adjust the initial position of the sheet: 1) If the target processing shape deviates greatly in the X-axis direction, it is necessary to correct the position by fine-tuning the standard coordinates of the X-axis to ensure accurate forming; 2) If there is a large offset in the Y-axis direction, adjust it by fine-tuning the standard coordinates of the Y-axis to achieve the desired processing shape; 3) If there is an offset in the Z-axis direction, the plane angle of the mold can be adjusted by raising the bottom of the mold to achieve the desired processing shape; The final forming contour can be obtained by further processing according to the adjusted parameters.

2. The incremental forming method of a thin-walled part with irregular offset according to claim 1, characterized in that: For spherical molds, adjustments are made according to the following formula: z = 0.000015x^3 + 0.000426yx^2 - 0.0657tx + 500yt; where z is the difference between the molded part and the mold height, x is the x-axis offset distance, y is the horizontal offset angle, and t is the tool offset distance percentage.

3. The incremental forming method of a thin-walled part with irregular offset according to claim 1, characterized in that: Before adjusting the initial position of the sheet, the following steps are also included: Step 1: Use CAD / CAM software to create a detailed 3D model of the target mold. After completing the 3D modeling, use the software to generate the corresponding NC code; Step 2: After the initial processing of the mold, install it on the progressive forming machine for precise positioning; Step 3: After completing the standard positioning of the mold, place the sheet to be processed in the forming area and ensure that the sheet is in uniform contact with the mold.

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