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Research Papers

Experimental and Numerical Investigation on Filling Roll Bending of Aluminum Alloy Integral Panel

[+] Author and Article Information
Han Xiao

School of Materials Science and Engineering,
Kunming University of Science and Technology,
Kunming 650093, People’s Republic of China;
Institute of Metal Research,
Chinese Academy of Sciences,
Shenyang 110016, People’s Republic of China
e-mail: zztixh@163.com

Shi-hong Zhang

e-mail: shzhang@imr.ac.cn

Jin-song Liu

e-mail: jsliu@imr.ac.cn

Ming Cheng

e-mail: mcheng@imr.ac.cn
Institute of Metal Research,
Chinese Academy of Sciences,
Shenyang 110016, People’s Republic of China

Hong-xi Liu

School of Materials Science and Engineering,
Kunming University of Science and Technology,
Kunming 650093, People’s Republic of China
e-mail: vipliuhx@yahoo.com.cn

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received December 16, 2011; final manuscript received August 19, 2012; published online November 12, 2012. Assoc. Editor: Brad L. Kinsey.

J. Manuf. Sci. Eng 134(6), 061011 (Nov 01, 2012) (7 pages) doi:10.1115/1.4007641 History: Received December 16, 2011; Revised August 19, 2012

Integral panels are widely used in aerospace industries. A filling roll bending process is proposed to form integral panels. Filling roll bending experiments of aluminum alloy integral panels were carried out. A 3D elastic–plastic finite element model of filling roll bending process was established and validated by experiment. The effects of filler and process parameters on the deformation homogeneity of the panels were analyzed by using experimental and numerical methods. The results indicate that the filler can improve the deformation homogeneity. With the increasing of the displacement of the top-roller from 5 mm to 40 mm, the experimental and simulation bending radii with filler all reduce, the experimental results reduce from 5806 mm to 190 mm, the simulation results reduce from 5924 mm to 199 mm, and the simulation springback rates with filler reduce from 0.92% to 0.15%. It is proved that high geometric accuracy of the integral panels can be obtained by using filling roll bending process.

Copyright © 2012 by ASME
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References

Figures

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Fig. 1

Principle of the filling roll bending process of integral panel

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Fig. 2

Integral panel: (a) structural diagram and (b) dimensions of section

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Fig. 3

Measured bending radius: (a) instrument and (b) schematic diagram

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Fig. 4

Finite element model of filling roll bending of the panel

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Fig. 5

Bent integral panels: (a) skin and (b) rib

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Fig. 6

Comparison of experimental and numerical bent panel

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Fig. 7

Experimental bending radii of integral panel with and without filler under different displacements

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Fig. 8

Experimental bending radii of different arcs with and without filler at displacement 40 mm

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Fig. 9

Experimental and simulation bending radii of bent panel with filler

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Fig. 10

Relationship between displacement and springback rate

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Fig. 17

Equivalent plastic strain of integral panel: (a) longitudinal and (b) transverse

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Fig. 12

Equivalent stress of integral panel at displacement 40 mm: (a) without filler and (b) with filler

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Fig. 11

Variations of equivalent stress during roll bending process: (a) the end of displacement of the top-roller; (b) rotary process of the bottom-roller; (c) the end of rotation of the bottom-roller; and (d) after unloading

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Fig. 16

Equivalent plastic strain of integral panel with filler: (a) rib and (b) skin

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Fig. 15

Equivalent plastic strain of integral panel without filler: (a) rib and (b) skin

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Fig. 14

Variations of equivalent plastic strain during roll bending process: (a) the end of displacement of the top-roller; (b) rotary process of the bottom-roller; (c) the end of rotation of the bottom-roller; and (d) after unloading

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Fig. 13

Shear stress of integral panel at displacement 40 mm: (a) without filler and (b) with filler

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