Research On Forming Mechanism And Control Algorithm Optimization Of Three-dimensional Continuous Free Bending Component

Three-dimensional free bending forming is an important technical innovation in the field of plastic forming of metal tubes.Compared with the traditional bending forming methods,it has greater technical advantages in forming multiple bending radii,variable bending radii,small bending radii,and continuous bending components without straight sections,and it has important application prospects in aerospace,nuclear energy equipment,automotive industry and other fields.At present,the researches on continuous free bending forming of metal tubes is not perfect,which restricts the engineering application of 3D free bending technology.Therefore,it is of great significance to carry out the research on the mechanism of 3D continuous free bending of metal tube and the optimization of equipment control system in order to realize the overall forming of complex continuous bending members.Based on the basic principle of three-dimensional continuous free-bending forming,this paper has carried out the systematic research work,including the constant curvature continuous free bending process and continuous variable curvature free bending process,the optimization and reliability verification of continuous free bending process,and the control algorithm optimization and upgrading of continuous free bending system.(1)A constant curvature continuous free bending forming process and a continuous variable curvature free bending forming process were established,and the process and mechanism of continuous free bending forming of metal tubes were mastered.By establishing the theoretical mechanical analysis model of continuous free bending,the stress-strain distribution law of metal tube in the process of free bending was studied,and the forming quality characteristics of continuous free bending were obtained.(2)Taking 6061-T6 aluminum alloy constant curvature spiral tube as an example,the process and optimization of continuous free-form bending with constant curvature were studied;taking the plane involute axis component and space involute axis component of 6061-T6 aluminum alloy as an example,the continuous variable curvature free bending forming process was studied.The stress-strain distribution,wall thickness distribution and cross-section distortion of continuous free-bending components were mastered,and it verified the reliability of the continuous free bending process of metal tube.(3)The algorithm was optimized and upgraded from the original bending segment control mode to the key point control mode.At the same time,based on the algorithm upgrades and the results of finite element simulations,and simplifying the front-end profile of the equipment to reduce the probability of interference,the experimental research on the constant curvature continuous free bending forming process and the continuous variable curvature free bending forming process were mastered,and further validated the reliability and stability of the continuous free bending forming process for tubes.