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TECHNICAL PAPERS

Process Design of Laser Forming for Three-Dimensional Thin Plates

[+] Author and Article Information
Jin Cheng, Y. Lawrence Yao

Department of Mechanical Engineering, Columbia University, New York, NY 10027

J. Manuf. Sci. Eng 126(2), 217-225 (Jul 08, 2004) (9 pages) doi:10.1115/1.1751187 History: Received December 01, 2002; Revised October 01, 2003; Online July 08, 2004
Copyright © 2004 by ASME
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References

Hsiao, Y.-C., Shimizu, H., Firth, L., Maher, W., and Masubuchi, K., 1997, “Finite Element Modeling of Laser Forming,” Section A-ICALEO 1997, pp. 31–40.
Magee,  J., Watkins,  K. G., and Steen,  W. M., 1998, “Advances in laser Forming,” J. Laser Appl., 10, pp. 235–246.
Bao, J., and Yao, Y. L., 1999, “Analysis and Predication of Edge Effects in Laser Bending,” Proceedings of ICALEO 1999, Section C, pp. 186–195.
Li,  W., and Yao,  Y. L., 2000, “Numerical and Experimental Study of Strain Rate Effects in Laser Forming,” ASME J. Manuf. Sci. Eng., 122, August, pp. 445–451.
Li, W., and Yao, Y. L., 2000, “Convex Laser Forming With High Certainty,” Trans. of the North American Manufacturing Research Conference of SME XXVIII, pp. 33–38.
Li,  W., and Yao,  Y. L., 2001, “Laser Bending of Tubes: Mechanism, Analysis and Prediction,” ASME J. Manuf. Sci. Eng., 123(4), pp. 674–681.
Ueda,  K., Murakawa,  H., Rashwan,  A. M., Okumoto,  Y., and Kamichika,  R., 1994, “Development of Computer-Aided Process Planning System for Plate Bending by Line Heating (Report 1)—Relation Between Final Form of Plate and Inherent Strain,” Journal of Ship Production, 10(1), pp. 59–67.
Ueda,  K., Murakawa,  H., Rashwan,  A. M., Okumoto,  Y., and Kamichika,  R., 1994, “Development of Computer-aided Process Planning System for Plate Bending by Line Heating (Report 2)—Practice for Plate Bending in Shipyard Viewed from Aspect of Inherent Strain,” Journal of Ship Production, 10(4), pp. 239–247.
Ueda,  K., Murakawa,  H., Rashwan,  A. M., Okumoto,  Y., and Kamichika,  R., 1994, “Development of Computer-aided Process Planning System for Plate Bending by Line Heating (Report 3)—Relation Between Heating Condition and Deformation,” Journal of Ship Production, 10(4), pp. 248–257.
Jang,  C. D., and Moon,  S. C., 1998, “An Algorithm to Determine Heating Lines for Plate Forming by Line Heating Method,” Journal of Ship Production, 14(4), pp. 238–245.
Shimizu, H., 1997, “A Heating Process Algorithm for Metal Forming by a Moving Heat Source,” M.S. Thesis, MIT.
Yu,  G., Patrikalakis,  N. M., and Maekawa,  T., 2000, “Optimal Development of Doubly Curved Surfaces,” Computer Aided Geometric Design, 17, pp. 545–577.
Cheng, J., and Yao, Y. L., 2001, “Process Synthesis of Laser Forming by Genetic Algorithms,” Proceedings of ICALEO 2001, Section D 604.
Liu, C., and Yao, Y. L., 2002, “Optimal and Robust Design of Laser Forming Process,” North American Manufacturing Research Institute of SME, May, in press.
Magee, J., Watkins, K. G., and Hennige, T., 1999, “Symmetrical Laser forming,” Proceedings of ICALEO 1999, pp. 77–86.

Figures

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Overall strategy for determining (a) scanning paths and (b) heating condition
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Desired shape I: pillow (dimension: 140*80*0.89 mm3, magnification ×5 in thickness for viewing clarity)
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Desired shape II: saddle (dimension: 140*80*0.89 mm3, magnification ×5 in thickness for viewing clarity)
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(a) Minimal principal in-plane strain, and (b) minimal principal bending strain for the pillow shape (dimension: 140*80*0.89 mm3)
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(a) Minimal principal in-plane strain, and (b) minimal principal bending strain for the saddle shape (dimension: 140*80*0.89 mm3)
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Vector plots of minimal principal in-plane strain for (a) pillow shape, and (b) saddle shape (the orientation of segments indicates strain direction and length of segments indicates strain magnitude)
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Scanning paths normal to the minimal principal in-plane strain for (a) pillow shape, and (b) saddle shape
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FEM-determined relationship between laser power, scanning velocity and (a) minimal principal in-plane strain, and (b) minimal principal bending strain, both averaged within the heating zone equal to the laser beam size of 4 mm (1010 mild steel sheet of 0.89 mm thick)
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Heating condition (laser power level in W and scanning velocity in mm/s (indicated by sign ’ ) indicated along scanning paths and superposed on magnitude contour plots of minimalprincipal in-plane strain for (a) pillow shape, and (b) saddle shape (a quarter of plates shown due to symmetry and see Figs. 5.4a and 5.5a color scales)
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Laser formed AISI1010 steel thin plates (dimension: 140*80*0.89 mm3) (a) pillow shape, & (b) saddle shape using scanning paths and heat conditions indicated in Fig. 9.
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Comparison of top-surface geometry of formed plate (in dotted lines) and desired shape (in solid lines) for (a) pillow shape, and (b) saddle shape. The formed plates were measured by CMM.
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(a) Minimal principal in-plane strain, and (b) minimal principal bending strain for the pillow shape of thicker plate (dimension: 140*80*5 mm3)
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(a) Minimal principal in-plane strain, and (b) minimal principal bending strain for the saddle shape of thicker plate (dimension: 140*80*5 mm3)

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