Papers by Author: Chun Guo Liu

Abstract: As a new technique to form sheet metal parts, Multi-point forming (MPF) also can be used on bending aluminum alloy profile. Since the Multi-Point Die (MPD) which replaces the traditional solid bending die is composed of many discrete punch elements, dimples always occur on the plate of profiles. To eliminate the dimpling defects, numerical simulation of the bending process with A6N01S-T5 aluminum alloy hollow profile using MPD were conducted. By comparing the bending effects on MPD with different size of punch elements and with different kind of elastic cushion, reasonable forming parameters were obtained. Pressing of Aluminum alloy profile with different radii on the MPD and solid die were simulated. The cross-section distortion indicated that the aluminum alloy profile can be formed with MPF technique while it has the advantage of flexibility. For the profile with large deformation, multi-step MPF method is a better choice due to its rapid reconfigurable characteristic.

Abstract: Although multi-point forming (MPF) is an advanced processing technique and has been investigated comprehensively as a metal working operation, there are few papers published to deal with MPF of polymers. The present paper reviews the features of MPF and evaluates the possibility of producing polymer components by means of MPF. The experimental research work makes use of PC sheets with a thickness of 3.82 mm. Numerical simulations were performed with the software ABAQUS, then spherical and saddle-shaped components were manufactured by MPF. The geometrical deviations between shaped components and their original CAD/CAM models were obtained to investigate the forming accuracy. The results confirm that MPF of PC sheet has potential for the manufacture of complex components.

Abstract: Aluminum alloy profile has been widely used in manufacturing industry for weight reduction. In the bending process of profile, the cross-section distortion is a common defect and also springback always happens in unloading process. In the paper, the bending process of a hollow profile with stiffener was simulated to optimize the forming parameters. Different bending radiuses and inner pressure were chosen in FEM analysis and the suitable radius and calculation equation of pressure for the given profile were obtained. The springback at different bending radiuses were studied to provide the principle of shape compensation.

Abstract: In reverse engineering, in order to analyze the accuracy of formed work-piece, the shape error between the formed work-piece and its CAD model need to be calculated. In this paper, a matching method on the basis of triangle mesh is proposed. This matching method includes three parts: pre-positioning, rough registration and fine registration. Firstly, the maximum projective plane of cloud data is designed to parallel to the xy plane through translation and rotation, and cloud data is translated by a vector which can be obtained with the point with the maximum z coordinate and the origin of coordinates. Secondly, cloud data is gradually rotated 360 degree around z axis confirm the angle making the error minimum. In this way, an initial value of ICP algorithm can be obtained, which can avoid the local convergence in the algorithm. Finally, ICP algorithm can be applied to calculate the surface error further. After matching, the error between work-piece and the CAD model can be calculated by interpolation based on triangle mesh. The results show that the matching method can obtain the higher matching accuracy.