The Experts below are selected from a list of 51 Experts worldwide ranked by ideXlab platform

Wei Chen - One of the best experts on this subject based on the ideXlab platform.

  • Analytical modeling and numerical simulation for three-roll Bending Forming of sheet metal
    The International Journal of Advanced Manufacturing Technology, 2013
    Co-Authors: Fu Zemin, Xiuli Tian, Wei Chen, Xingyan Yao
    Abstract:

    The three-roll Bending Forming of sheet metal is an important and flexible manufacturing process due to simple configuration. It is suitable for Forming large sheet parts with complex, curved faces. Most researches on roll Bending Forming of large workpiece are mainly based on experiments and explain the process through macroscopic metal deformation. An analytical model and ABAQUS finite element model (FEM) are proposed in this paper for investigating the three-roll Bending Forming process. A reasonably accurate relationship between the downward inner roller displacement and the desired springback radius (unloaded curvature radius) of the bent plate is yielded by both analytical and finite element approaches, which all agree well with experiments. Then, the three-roll Bending Forming process of a semi-circle-shaped workpiece with 3,105 mm (length) × 714 mm (width) × 545 mm (height) is simulated with FEM established by the optimum tool and process parameters. Manifested by the experiment for three-roll Bending Forming of this workpiece, the numerical simulation method proposed yields satisfactory performance in tool and process parameters optimization and workpiece Forming. It can be taken as a valuable mathematical tool used for three-roll Bending Forming of large area sheet metal.

  • using genetic algorithm back propagation neural network prediction and finite element model simulation to optimize the process of multiple step incremental air Bending Forming of sheet metal
    Materials & Design, 2010
    Co-Authors: Lin Chen, Wei Chen
    Abstract:

    Abstract Using neural network to predict punch radius based on the results of air-Bending experiments of sheet metal is a high efficiency work in spite of little error. A three-layer back propagation neural network (BPNN) is developed to best fit this discrete engineering problem involving many parameters of air-Bending Forming. A genetic algorithm (GA) is used to optimize the weights of neural network for minimizing the error between the predictive punch radius and the experimental one. Then, with the predicted punch radius and other geometrical parameters of a tool, 2D and 3D ABAQUS finite-element models (FEM) are established, respectively. The original Forming process of multiple-step incremental air-Bending of sheet metal, obtained from geometric planning for semiellipse-shaped workpiece, is simulated using the FEM. This process is further adjusted with simulation-optimization results, because of existing large errors in the workpiece simulated with the original Forming process. Finally, a semiellipse-shaped workpiece, with average errors of +0.61/−0.62 mm, is manufactured with the optimized adjustment process. The experimental results show that the punch design method is feasible with the prediction model of GA-BPNN, and the means of optimizing process with FEM simulation is effective. It can be taken as a new approach for punch and process design of multiple-step incremental air-Bending Forming of sheet metal.

Lin Chen - One of the best experts on this subject based on the ideXlab platform.

  • using genetic algorithm back propagation neural network prediction and finite element model simulation to optimize the process of multiple step incremental air Bending Forming of sheet metal
    Materials & Design, 2010
    Co-Authors: Lin Chen, Wei Chen
    Abstract:

    Abstract Using neural network to predict punch radius based on the results of air-Bending experiments of sheet metal is a high efficiency work in spite of little error. A three-layer back propagation neural network (BPNN) is developed to best fit this discrete engineering problem involving many parameters of air-Bending Forming. A genetic algorithm (GA) is used to optimize the weights of neural network for minimizing the error between the predictive punch radius and the experimental one. Then, with the predicted punch radius and other geometrical parameters of a tool, 2D and 3D ABAQUS finite-element models (FEM) are established, respectively. The original Forming process of multiple-step incremental air-Bending of sheet metal, obtained from geometric planning for semiellipse-shaped workpiece, is simulated using the FEM. This process is further adjusted with simulation-optimization results, because of existing large errors in the workpiece simulated with the original Forming process. Finally, a semiellipse-shaped workpiece, with average errors of +0.61/−0.62 mm, is manufactured with the optimized adjustment process. The experimental results show that the punch design method is feasible with the prediction model of GA-BPNN, and the means of optimizing process with FEM simulation is effective. It can be taken as a new approach for punch and process design of multiple-step incremental air-Bending Forming of sheet metal.

Jie Tao - One of the best experts on this subject based on the ideXlab platform.

  • theoretical analysis finite element modelling and experimental investigation of manufacturing convoluted spiral tubes through free Bending Forming technology
    The International Journal of Advanced Manufacturing Technology, 2021
    Co-Authors: Wei Wang, Ali Abd Elaty, Xueshan Bai, Jin Sun, Myounggyu Lee, Wenbin Wei, Hao Chen, Xunzhong Guo, Jie Tao
    Abstract:

    The free Bending Forming (FBF) technology is a new die-less Forming process suitable for Bending complex-shaped thin-walled tubes with several Bending radii. A new theoretical model of convoluted spiral tubes manufactured through FBF technology is proposed in this investigation for revealing and understanding the parameters of manufacturing the spiral tubes using FBF technology. After that, finite element modelling and experimentation were performed to verify the accuracy and reliability of the proposed theoretical model. The max error determined by comparing the experimental results with those acquired from the theoretical analysis is less than 7%. This verifies the reliability and the accuracy of the new theoretical analysis. Afterwards, the Forming limit of a convolute spiral tube manufacturing by FBF technology is explored. It is realized that the spiral diameter (D) was affected by distance A which is the distance between the front end of the guide mechanism and the centre of Bending die in Z direction; and eccentricity (U). In addition, it is detected that D is directly proportional with distance A and inversely proportional with distance U, where D increased by increasing distance A and decreasing U.

  • springback analysis of different a values of cu and al tubes in free Bending Forming technology experimentation and finite element modeling
    The International Journal of Advanced Manufacturing Technology, 2021
    Co-Authors: Wei Wang, Ali Abd Elaty, Hao Chen, Qiucheng Yang, Yizhou Shen, Jie Tao
    Abstract:

    In tube free Bending Forming technology, the springback behavior affects the bent tubes’ Forming accuracy and quality. Thus, in this investigation, the springback behaviors of T2-Cu and AA6061-T6 tubes manufactured by free Bending technology were studied experimentally and using finite element modeling. The Bending radius of the formed tubes was measured in ABAQUS combined with the geometric calculation. After investigating the different A-values (sufficient length of deformation zone) of Cu and Al tubes, it was found that the higher the A-value, the higher the Bending angle, the lower the Bending radius, and the larger the springback angle. The changes of both Bending and material properties affect the springback to specific values. The tube Forming’s stress peak occurred in the Forming segment, where the springback angle is the highest, and the outer springback is higher than the inner side at the same A-value and position. Under the same Forming parameters, each section’s strain variation and springback angle in the Bending process of T2-Cu tubes is higher than that of AA6061-T6 tubes. The simulation results were in remarkable agreement with those obtained from experimentation, proving the simulation’s reliability and accuracy.

Ali Abd Elaty - One of the best experts on this subject based on the ideXlab platform.

  • theoretical analysis finite element modelling and experimental investigation of manufacturing convoluted spiral tubes through free Bending Forming technology
    The International Journal of Advanced Manufacturing Technology, 2021
    Co-Authors: Wei Wang, Ali Abd Elaty, Xueshan Bai, Jin Sun, Myounggyu Lee, Wenbin Wei, Hao Chen, Xunzhong Guo, Jie Tao
    Abstract:

    The free Bending Forming (FBF) technology is a new die-less Forming process suitable for Bending complex-shaped thin-walled tubes with several Bending radii. A new theoretical model of convoluted spiral tubes manufactured through FBF technology is proposed in this investigation for revealing and understanding the parameters of manufacturing the spiral tubes using FBF technology. After that, finite element modelling and experimentation were performed to verify the accuracy and reliability of the proposed theoretical model. The max error determined by comparing the experimental results with those acquired from the theoretical analysis is less than 7%. This verifies the reliability and the accuracy of the new theoretical analysis. Afterwards, the Forming limit of a convolute spiral tube manufacturing by FBF technology is explored. It is realized that the spiral diameter (D) was affected by distance A which is the distance between the front end of the guide mechanism and the centre of Bending die in Z direction; and eccentricity (U). In addition, it is detected that D is directly proportional with distance A and inversely proportional with distance U, where D increased by increasing distance A and decreasing U.

  • springback analysis of different a values of cu and al tubes in free Bending Forming technology experimentation and finite element modeling
    The International Journal of Advanced Manufacturing Technology, 2021
    Co-Authors: Wei Wang, Ali Abd Elaty, Hao Chen, Qiucheng Yang, Yizhou Shen, Jie Tao
    Abstract:

    In tube free Bending Forming technology, the springback behavior affects the bent tubes’ Forming accuracy and quality. Thus, in this investigation, the springback behaviors of T2-Cu and AA6061-T6 tubes manufactured by free Bending technology were studied experimentally and using finite element modeling. The Bending radius of the formed tubes was measured in ABAQUS combined with the geometric calculation. After investigating the different A-values (sufficient length of deformation zone) of Cu and Al tubes, it was found that the higher the A-value, the higher the Bending angle, the lower the Bending radius, and the larger the springback angle. The changes of both Bending and material properties affect the springback to specific values. The tube Forming’s stress peak occurred in the Forming segment, where the springback angle is the highest, and the outer springback is higher than the inner side at the same A-value and position. Under the same Forming parameters, each section’s strain variation and springback angle in the Bending process of T2-Cu tubes is higher than that of AA6061-T6 tubes. The simulation results were in remarkable agreement with those obtained from experimentation, proving the simulation’s reliability and accuracy.

Wenxian Zhang - One of the best experts on this subject based on the ideXlab platform.

  • study on multiple step incremental air Bending Forming of sheet metal with springback model and fem simulation
    The International Journal of Advanced Manufacturing Technology, 2009
    Co-Authors: Wenxian Zhang
    Abstract:

    A mathematical model of springback radius was developed with dimensional analysis and orthogonal test. With this model, the punch radius could be solved for Forming high-precision semiellipse-shaped workpieces. With the punch radius and other geometrical parameters of a tool, a 2D ABAQUS finite-element model (FEM) was established. Then, the Forming process of sheet metal multiple-step incremental air Bending was simulated with the FEM. The result showed that average errors of the simulated workpiece were +0.68/−0.65 mm, and provided the process data consisting of sheet feed rate, punch displacement and springback angle in each step. A semiellipse-shaped workpiece, whose average errors are +0.68/−0.69 mm, was made with the simulation data. These results indicate that the punch design method is feasible with the mathematical model, and the means of FEM simulation is effective. It can be taken as a new approach for sheet metal multiple-step incremental air-Bending Forming and tool design.