Transactions of Materials and Heat Treatment

Title：Control and optimization of wrinkling during robotic bending for thin-walled aluminum alloy tube

Authors： Guo Xunzhong1 2 Xu Xiangyong1 Liu Chunmei1 2 Bai Xueshan3 Zhang Kun3 Sun Zhenbiao1 Shen Rantao1

Unit： 1. State Key Laboratory of Mechanics and Control for Aerospace Structures Nanjing University of Aeronautics and Astronautics 2. Zhejiang Province Key Laboratory of Aerospace Metal Tube Forming Technology and Equipment Zhejiang King-Mazon Intelligent Manufacturing Co. Ltd. 3. AVIC Shenyang Aircraft Industial (Group) Co. Ltd.

KeyWords： thin-walled aluminum alloy tube robotic bending technology geometric micro-defect wrinkling control response surface optimization

ClassificationCode：TG391

year,vol(issue):pagenumber：2023,48(5):205-220

Abstract：

Born in the context of Industry 4.0, robotic tube bending technology is a new and highly flexible tube bending technology, which enables fully automatic and rapid bending of long and thin tubes. While bending and rotating, the robot-controlled end bending device can feed along the direction of the tube axis, which can improve the wall thickness reduction of bent tubes, but on the other hand increase the tendency of wrinkling. Therefore, taking Al6061 aluminum alloy tube as the object, the optimization and control of wrinkling during the thin-walled tube bending by robot were carried out. Selecting the wavelength at the lowest energy consumption during the model calculation after embedding geometric micro-defect, wrinkling morphology and scaling factor that was the most similar to the actual sample as the optimal parameters, the finite element model of robotic tube bending with embedded geometric micro-defects was established. Using the combination method of the finite element model with geometric micro-defect coupling, response surface optimization analysis and forming experiments, a response surface regression prediction model for wrinkling was established. Through the obtained response surface and contour map, the influence laws of process parameter coupling on wrinkling during robotic bending of Al6061 aluminum alloy thin-walled tube was revealed, and the optimal forming process parameters were obtained. And then the reliability of the wrinkling prediction model and the finite element model embedded geometric micro-defects were further validated.

Funds：

国家自然科学基金青年基金（52105362）；国家自然科学基金面上基金（52175328）；江苏省自然科学基金青年基金（BK20210310）

作者简介：郭训忠（1981-），男，博士，教授,E-mail：guoxunzhong@nuaa.edu.cn;通信作者：刘春梅（1989-），女，博士，讲师,E-mail：liuchunmei@nuaa.edu.cn

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