基于响应面法的单点增量成形过程变形能优化

摘要/Abstract

摘要： 单点增量成形过程中的变形能对加工成本控制及工具头与材料之间的热效应和摩擦效应有直接影响。以典型圆锥形制件为研究对象，采用BBD实验方法，设计四因素三水平实验方案，利用响应面法研究工具头直径d、层间距Z、板厚t和成形角α对变形能的影响，并得到变形能的多元二次预测模型，最后以变形能最小为目标对该模型进行优化。实验结果表明：板厚对变形能的线性影响最显著，随着板厚的增大变形能增大，工具头直径越大所需变形能越大，成形角增大时所需的变形能增大；变形能最小的工艺参数组合是工具头直径4.0mm、层间距0.95mm、板厚0.57mm、成形角45°。

关键词: 单点增量成形, 响应面法, 变形能, 实验设计

Abstract: The deformation energy in single point incremental forming processes had direct impact on the processing costs, also the heats and the wear effects between the tools and formed materials. A box-behnken design(BBD) for cone parts forming processes was performed, which considered the plan of four factors and three levels. The effects of tool diameter, step down, sheet thickness and wall angle on deformation energy were investigated. Meanwhile, the deformation energy was predicted by quadratic equations. Finally, the model was optimized with minimum deformation energy. The results show that, sheet thickness presents the most significant liner effects on deformation energy, while deformation energy increases with the increases of sheet thicknesses, tool diameters and wall angles. At last, tool diameter 4.0mm, step down 0.95mm, sheet thickness 0.57mm and wall angle 45° are combined as the best parameters for the minimum deformation energy.

Key words: single point incremental forming, response surface methodology, deformation energy, experimental design

中图分类号:

TG386

姚梓萌, 李言, 杨明顺, 张敬冲, 张成兴. 基于响应面法的单点增量成形过程变形能优化[J]. 中国机械工程.

YAO Zimeng, LI Yan, YANG Mingshun, ZHANG Jingchong, ZHANG Chengxing. Optimization of Deformation Energy in Single Point Incremental Forming Processes Using Response Surface Methodology[J]. China Mechanical Engineering.

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