Flexible stretch bending of AA6082-T4 and WT profiles using reconfigurable tooling
Chanmi Moon, Sigmund A Tronvoll, Torgeir Welo, Jun Ma
Abstract. Ensuring high dimensional accuracy in metal forming processes is critical, as it can significantly affects the subsequent operations as well as the quality of final product. A comprehensive understanding and control of factors influencing deformation behavior, such as springback and local distortions, are vital for enhancing the required dimensional accuracy. This study examines the local and global deformation characteristics of AA6082-WT (W-temper) and AA6082-T4 profiles during a novel flexible stretch bending process, through FEA, incorporating an innovative multi-point reconfigurable die system. To investigate dimensional accuracy of AA6082 profiles in different tempers- thus different mechanical properties, across three different die radii (R1000, R1500, and R1750 mm) in global and local deformation level, simulations are conducted. The findings emphasize the impact of the discrete multi-point tool on overall deformation behavior following springback, including chord height during kinematically controlled bending and stretching. Moreover, the study identifies the range of local deformation required to ensure that global deformation remains within acceptable tolerance limits for products formed using reconfigurable multi-point tooling systems.
Keywords
AA6082 Profile, Flexible Stretch Forming, Reconfigurable Tooling, Dimensional Accuracy
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Chanmi Moon, Sigmund A Tronvoll, Torgeir Welo, Jun Ma, Flexible stretch bending of AA6082-T4 and WT profiles using reconfigurable tooling, Materials Research Proceedings, Vol. 54, pp 1036-1045, 2025
DOI: https://doi.org/10.21741/9781644903599-112
The article was published as article 112 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] D.F. Walczyk, & D.E. Hardt. (1998). Design and analysis of reconfigurable discrete dies for sheet metal forming. Journal of Manufacturing Systems, 17(6), 436-454. https://doi.org/10.1016/S0278-6125(99)80003-X
[2] J.S. Yoon, S.E. Son, W.J. Song, J. Kim, & B.S. Kang. (2014). Study on flexibly reconfigurable roll forming process for multi-curved surface of sheet metal. International journal of precision engineering and manufacturing, 15, 1069-1074. https://doi.org/10.1007/s12541-014-0438-2
[3] Y. Li, C. Lv, J. Liang, & C. Liang. (2023). Study on the effect of multi-point stretch-bending processing conditions on the section distortion of complex cross-sectional parts. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 237(1-2), 91-104. https://doi.org/10.1177/09544054221092917
[4] J. Ma, S.A. Tronvoll, J. Blindheim, G. Ringen, & T. Welo. (2024). Reconfigurable Tooling for Customized Stretch Forming of Profiles. In International Manufacturing Science and Engineering Conference (Vol. 88117, p. V002T06A030). American Society of Mechanical Engineers. https://doi.org/10.1115/MSEC2024-125666
[5] S. Yang, Y. Li, J. Liang, Y.Wen, C. Liang, & Q. Han. (2024). Adaptive multi-point flexible-bending technology for improving the quality of profile using discrete dies driven by snake-shaped motion mechanism. Journal of Materials Processing Technology, 325, 118297. https://doi.org/10.1016/j.jmatprotec.2024.118297
[6] H. Zhao, F. Shi, & Y. Hu. (2024). Springback ratio matrix-based description and compensation for precision forming of doubly curved plates using reconfigurable dies. The International Journal of Advanced Manufacturing Technology, 130(11), 5853-5867. https://doi.org/10.1007/s00170-023-12933-6
[7] J. Liang, C. Chen, Y. Li, & C. Liang. (2020). Effect of roller dies on springback law of profile for flexible 3D multi-point stretch bending. The International Journal of Advanced Manufacturing Technology, 108, 3765-3777. https://doi.org/10.1007/s00170-020-05655-6
[8] C. Moon, J. Ma, & M.G. Lee. (2024). Dynamics of Portevin-Le Chatelier (PLC) bands and fracture behavior of W-tempered 7075 aluminum alloys with different cooling methods. Materials Science and Engineering: A, 914, 147162. https://doi.org/10.1016/j.msea.2024.147162
[9] J. Ma, and T. Welo. (2021) Analytical Springback Assessment in Flexible Stretch Bending of Complex Shapes. Int. J. Mach. Tools Manuf., 160, p. 103653. https://doi.org/10.1016/j.ijmachtools.2020.103653
[10] K. Lee, C. Moon, & M.G. Lee (2021). A review on friction and lubrication in automotive metal forming: Experiment and modeling. International Journal of Automotive Technology, 22, 1743-176. https://doi.org/10.1007/s12239-021-0150-z
[11] J. Ma, S.A. Tronvoll, & T. Welo, 2023, “Prediction and Analysis of Real-Time Forces in Novel 3D Flexible Rotary Stretch Forming of Complex Profiles,” CIRP J. Manuf. Sci. Technol., 43, pp. 158–169. https://doi.org/10.1016/j.cirpj.2023.04.001
