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Xunzhong Guo
Editor
Flexible Metal Forming
Technologies
Principles, Process and Equipment
Editor
Xunzhong Guo
School of Materials Science
and Technology
Nanjing University of Aeronautics
and Astronautics
Nanjing, Jiangsu, China
ISSN 2195-9862 ISSN 2195-9870 (electronic)
Springer Tracts in Mechanical Engineering
ISBN 978-981-19-1347-1 ISBN 978-981-19-1348-8 (eBook)
https://doi.org/10.1007/978-981-19-1348-8
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Preface
Flexible forming technologies are the methods of precise plastic forming of prod-
ucts by using flexible forming equipment and flexible tools and dies. The outstanding
advantages of flexible forming technologies are strong and wide adaptability and low
mold cost. Nowadays, many kinds of products in aerospace and different engineering
applications are increasingly showing diversified and personalized rapid manufac-
turing requirements. The traditional manufacturing technologies, which depend on
molds, have obvious limitations in terms of response speed and manufacturing cost.
Using flexible forming technologies, it is easy to realize efficient manufacturing and
intelligent manufacturing. Thus, it takes too much attention recently all over the
world.
Nevertheless, flexible forming technologies are carried out under less and uncon-
strained conditions. The flow of the materials is relatively free, the shape and size of
components are not easy to control, and there are various forms of defects. There-
fore, flexible forming technologies face some difficulties in forming and controlling
processes during manufacturing thin-walled complex-shaped components.
Recently, related research and development institutions in China, Japan, Germany,
the USA, and many other countries are engaged in the research and development
of advanced flexible forming technologies. Notwithstanding, so far, there is still
a lack of a systematic academic monograph on the flexible forming of complex
metal components in the aspects of forming mechanism, formability control methods,
material flow, equipment design, and configuration.
The Flexible Forming Technologies and Equipment research group at Nanjing
University of Aeronautics and Astronautics (NUAA) is the research team established
based on the country’s major needs in aerospace and nuclear energy engineering. The
flexible forming technologies research group has solid experience and outstanding
results in designing and manufacturing flexible forming technologies such as flexible
bending forming, incremental forming, spinning forming, and multi-point forming.
Meantime, lots of researches on key technologies for process simulation optimization
and defect control have been carried out. The research results of flexible forming
technology have obtained critical engineering applications in the relevant engineering
fields, such as aerospace, nuclear energy engineering, automobile, and petrochemical.
v
vi Preface
In order to make the research results play a greater role, through carefully combing
and summarizing in detail, this book entitled “Flexible metal forming technologies:
Principles, process and equipment” has been done.
The book is divided into nine chapters, and a quick preview of the contents is
given as follows:
Chapter 1 introduces the main direction of manufacturing technology innovation
in recent years, analyzes the shortcomings of traditional manufacturing technology
based on customer needs, expounds on the development status and latest research
results of flexible forming technology in the field of metal products manufacturing,
and summarizes the typical characteristics and development trend of flexible forming
technology from the aspects of flexible forming equipment, process, and materials.
Chapter 2 introduces the forming principle, the deformation mechanism during
the incremental forming, the different variants of incremental forming, and the
key forming process at different temperatures and different materials. Besides, the
research progress of the incremental forming technology and equipment is also
discussed.
Chapter 3 introduces the forming principle, spinning equipment, and tooling
design of the flexible spinning forming technology. Then starting from three
processes of thin-wall and revolving body components of spinning forming,
bimetallic composite tube of spinning forming, and power spinning of thin-walled
components, through the combination of simulation and experiment, the flexible
spinning forming technology is deeply discussed.
Chapter 4 introduces the multi-point forming technology (MPF) in detail from the
aspects of forming principle, shape adjustment mechanism, multi-point die system
design, finite element simulation, and multi-point forming process of typical compo-
nents. In addition, a multi-point rubber forming process has been developed by
combining multi-point forming technology with rubber forming technology.
Chapter 5 systematically introduces the principles of flexible forming technolo-
gies, the mechanism of forming and controlling process, the design and the config-
uration rules for flexible forming technologies, materials flow, and forming defects
during the forming process. Furthermore, the current forming simulation and shape
control solution in flexible roll forming are introduced. Finally, comprehensive
summary and outlook of this technology are discussed.
Chapter 6 introduces 3DQ technology which can realize the high-precision inte-
gral forming of three-dimensional components with high-strength and complex
features. Using the optimized robot trajectory and process parameters, 3DQ bending
components with satisfactory shape and performance can be formed.
Chapter 7 introduces the 3D free bending forming technology of 3D complex
hollow components. Firstly, it introduces the classification of three-dimensional free
bending equipment and analyzes the principles of three-axis free bending, six-axis
free bending and free bending based on parallel mechanism, analysis of forming
trajectory algorithm, and the structure of key molds. Finally, the concept of warm
free bending is proposed for the difficult-to-deform titanium alloy pipe, and the
feasibility of the process is verified by finite element simulation and experiment.
Preface vii
Chapter 8 introduces the flexible roll forming technology of complex profile
bending components. Starting from the principle of roll forming, the trajectory anal-
ysis of roll forming and the principle of mold design are introduced. And through the
finite element simulation and experiment, the wall thickness distribution law, the axis
dimension accuracy of the plane and three-dimensional roll bending of aluminum
alloy rectangular tube are studied, respectively, which provides technical guidance
for the actual production and processing.
Chapter 9 introduces a new type of tube die less forming technology called “Flex-
ible tube die less forming”, using heating equipment or forming tool to replace the
constraint of forming die on the tube, so as to make the material deform according to
the preset requirements and realize the die less forming of tube. Due to this feature,
flexible tube die less forming is suitable for flexible forming of some tubes with
complex, irregular, or even regular-changing cross-section shapes.
This book introduces the principles of flexible forming technologies to manu-
facture thin-walled complex-shaped components, the mechanism of controlling the
material flow, and the design and the configuration of flexible forming technologies’
equipments and tools systematically. The relevant content will play a significant
guiding role for researchers, engineers, and graduate and undergraduate students;
hence, the book has a good market prospect.
Gratefully appreciate your interest and the time taken to read this book entitled
“Flexible metal forming technologies: Principles, process and equipment” and hope
it is worthwhile to add some unique opinions to this rapidly developing flexible metal
forming technology.
Nanjing, China Prof. Dr. Xunzhong Guo
2021
Acknowledgments
First of all, I gratefully appreciate the financial support from the National Natural
Science Foundation of China (Projects Nos. U1937206, 52175328, 52105362,
52105360, 51711540301, 51205196 and 5201101342), Jiangsu Province Key
Research and Development Project (No. BE2019007-2), the Aeronautical Science
Foundation of China (Project No. 2016ZE52047), the Natural Science Foundation
of Jiangsu Province (Project No. BK20151469, BK20210310, BK20200453), the
Qing Lan Project, Jiangsu Provincial Department of Education, China, Opening
Project of Jiangsu Key Laboratory of Advanced Structural Materials and Applica-
tion Technology (No. ASMA201903), Opening Project of State Key Lab of Digital
Manufacturing Equipment & Technology (No. DMETKF2021004), and the Funda-
mental Research Funds for the Central Universities (Projects Nos. NT2020015 and
NS2021046), who supported my research work on flexible forming technologies.
I appreciate my Ph.D. supervisors Prof. Jie Tao who gave me very serious teaching
and support. I appreciate the members of flexible forming group: Senior Researcher
Yizhou Shen, Associate Professor Huaguan Li, Lecturer Hui Wang, Lecturer Cheng
Cheng, Lecturer Chunmei Liu, Assistant Miss Gui Wei, and Research Associate
Dr. Ali Abd El-Aty for their help and support on flexible forming. I also appreciate
Prof. Albert Sedlmaier of data M Sheet Metal Solutions GmbH in Germany, Dr. Yong
Sun of the Ultra-X Lab of Shenzhen Institute for Advanced Study of University of
Electronic Science and Technology of China, and Xiaohong Zheng of Guangdong
Gaopu Bending Technology Co. Ltd. and Guangdong Bosai CNC Machine Tool Co.
Ltd. that contributed a lot to the better understanding of flexible forming technologies.
Furthermore, I wish to thank my Ph.D. and M.D. students, Mr. Qiucheng
Yang, Mr. Shenghan Hu, Mr. Shuo Zheng, Mr. Cong Wu, Mr. Zushu Huang,
Mr. Hao Zhang, Mr. Jiaxin Guo, Mr. Zijie Wang, Mr. Chao Pan, Mr. Zhenbiao Sun,
Mr. Haoran Luo, Mr. Shixuan Liu, Miss. Wenfeng Guo, Mr. Yangyang Deng,
Mr. Haoqi Ni, Mr. Rensixu Zhang, and Mr. Shaoxin Li for their serious diligent
work for our research projects. Many of the results as presented in this book actually
have been achieved together with my colleagues and students.
ix
x Acknowledgments
I also gratefully acknowledge the copyright permission from the following
publishers including Springer, Elsevier, Maney Publishing, IOP Publishing, and AIP
Publishing for the reproduction of the author’s published journal papers.
In particular, I wish to thank my wife Wei Yan for her encouragement and support
for my scientific research. At the same time, I would like to thank my son Yihang
and daughter Yining. After work every day, their welcome and hug swept away my
fatigue. All of them are an important driving force for me to engage in scientific
research of flexible forming technology.
