Research On Incremental Bending Forming System Based On Digital Twin

With the rapid development of science technology and information technology,traditional manufacturing is facing tremendous pressure.Although China is a big manufacturing country,there is still a gap in the aspect of automation,informatization and independent innovation capabilities between developed countries.In the context of Industry 4.0,the implementation of Made in China 2025 strategy is intended to combine new technologies to enhance the level of intelligence in the domestic manufacturing industry.Digital twin,as one of the elements of Industry 4.0,helps to realize the interconnection between the physical space and the information space in the manufacturing process,and promote the development of intelligent manufacturing.In the case of forming small batches of ship plates with specific curvatures,some traditional forming methods have shortcomings: first,several new dies are needed to form the smallbatched parts with specific curvatures,and thus leading to huge manufacturing costs.;second,the large forming force in the forming process contributes to high energy consumption and low forming efficiency.According to the existing problems mentioned above,one noval incremental bending process is proposed to save the cost and improve the forming accuracy and efficiency.However,at this stage,most stamping processes lack dynamic monitoring during the forming process,and the physical space and information space lack interactive communication,and it is often impossible to judge the forming situation in time during the manufacturing process.In order to solve the obstacles of information interaction in forming.In this paper,combined with digital twin technology,the study on the incremental bending system based on digital twin is put forward.The content of the paper mainly includes the following parts:Firstly,for the establishment of the virtual space model,the physical equipment in the incremental bending forming is used as the object.Based on the proposed modeling process,the behavior characteristics,motion rules,lightweight and interactivity of the modeling rules are considered.And it is completed by combining Solid Works and Visual Components to construct virtual space.Facing the lack of information about the forming process,finite element simulation analysis method is used to generate data to provide a reference for the forming process information.Then,starting from the five-dimensional structure of digital twin,the operating mechanism of incremental bending forming system based on digital twin is stuided.The physical space entities,digital twin data,system services and the connections between them are entirely explained.The database is established in the digital twin data layer,and is access to server data through script programming in the logic layer,and transfer the data to the virtual space to drive model to realize mapping with the physical space,so as to realize the condition monitoring during the incremental bending process.Finally,after building the incremental bending forming system,single-point stamping experiments are used to verify the feasibility and reliability of the system.Afterwards,based on the minimum energy method’s forming trajectory theory,the loading paths of incremental bending for specific single curvature and variable curvature metal plates are calculated,and the real-time punch force and support pressure data of the system during the forming process are compared with the data of finite element simulation analysis in real time.And the threedimensional vision scanning is used to obtain the forming effect analysis of the metal plate after forming,which helps to better monitor incremental bending forming status,cheack forming quality and analyse forming error,and it reflects the "service layer" of the system.Through the above research,this paper solves the data information interaction of physical equipment,punch,supports and other components in the process of incremental bending,and can monitor the forming state of the metal sheet and the motion state of the CNC machine tool in real time and make incremental bending more intelligent.Finally,in the process of forming metal plates with specific curvature,online data comparison provides forming monitoring.After the forming is completed,through three-dimension vision scanning,the errors of the singlecurvature plate and the variable-curvature plate with the target curvature are 7.4% and 10.5%respectively,and the system guarantees good forming effect.The construction concept of the entire system provides an effective reference plan for the application of digital twins to stamping processes or other manufacturing processes.