Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions

Dimensional accuracy of incoming components is crucial for automated welding and assembly in mass volume production. However, thin-walled extrusions made to industrial standards show severe dimensional variations, including gap opening, sidewall inclination, local convexity, and so on. Thus, one maj...

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Autores principales:	Xianyan Zhou, Torgeir Welo, Jun Ma, Sigmund A. Tronvoll
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	dimensional correction stretching local-bending gap opening thin-walled components Mining engineering. Metallurgy TN1-997
Acceso en línea:	https://doaj.org/article/73988c885b0c42818c5294b67fe01a33
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spelling	oai:doaj.org-article:73988c885b0c42818c5294b67fe01a332021-11-25T18:21:56ZDeformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions10.3390/met111117862075-4701https://doaj.org/article/73988c885b0c42818c5294b67fe01a332021-11-01T00:00:00Zhttps://www.mdpi.com/2075-4701/11/11/1786https://doaj.org/toc/2075-4701Dimensional accuracy of incoming components is crucial for automated welding and assembly in mass volume production. However, thin-walled extrusions made to industrial standards show severe dimensional variations, including gap opening, sidewall inclination, local convexity, and so on. Thus, one major challenge is to provide a low-cost correction method to improve the dimensional accuracy at a level demanded by automated assembly and/or product fit-up. A novel correction method called transverse stretch and local bending (TSLB) has recently been developed, enabling one to efficiently correct the dimensional deviations in thin-walled, U-channel profiles at a low cost. However, the lack of in-depth understanding of the underlying mechanism makes it challenging to efficiently optimise and control the process. In this study, the feasibility of this new technique was experimentally validated by four groups of TSLB tests with different profile dimensions, showing a dimensional accuracy improvement of about 92% compared with the as-received parts. The evolution of the critical dimensional characteristics, including gap opening and bottom convexity, is analysed numerically throughout four stages consisting of inserting, releasing, calibration, and springback. It is found that the inserting stage greatly reduces the dimensional deviations in a pure bending state, while the calibration stages further minimise the deviations in the bending and transverse stretching combined state. In addition, the wedge angle of the tool is found to be critical to the dimensional accuracy improvement. The low wedge angle facilitates the correction of sidewall inclination and gap opening, while the high wedge angle contributes to mitigating bottom convexity. The overall outcome of this study enhances the fundamental understanding of the effects of in-process stretching and local-bending on the dimensional capabilities of U-channel extrusions. This can ultimately generate guidelines that will lead to new application areas of aluminium extrusions in highly competitive marketplaces.Xianyan ZhouTorgeir WeloJun MaSigmund A. TronvollMDPI AGarticledimensional correctionstretchinglocal-bendinggap openingthin-walled componentsMining engineering. MetallurgyTN1-997ENMetals, Vol 11, Iss 1786, p 1786 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	dimensional correction stretching local-bending gap opening thin-walled components Mining engineering. Metallurgy TN1-997
spellingShingle	dimensional correction stretching local-bending gap opening thin-walled components Mining engineering. Metallurgy TN1-997 Xianyan Zhou Torgeir Welo Jun Ma Sigmund A. Tronvoll Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions
description	Dimensional accuracy of incoming components is crucial for automated welding and assembly in mass volume production. However, thin-walled extrusions made to industrial standards show severe dimensional variations, including gap opening, sidewall inclination, local convexity, and so on. Thus, one major challenge is to provide a low-cost correction method to improve the dimensional accuracy at a level demanded by automated assembly and/or product fit-up. A novel correction method called transverse stretch and local bending (TSLB) has recently been developed, enabling one to efficiently correct the dimensional deviations in thin-walled, U-channel profiles at a low cost. However, the lack of in-depth understanding of the underlying mechanism makes it challenging to efficiently optimise and control the process. In this study, the feasibility of this new technique was experimentally validated by four groups of TSLB tests with different profile dimensions, showing a dimensional accuracy improvement of about 92% compared with the as-received parts. The evolution of the critical dimensional characteristics, including gap opening and bottom convexity, is analysed numerically throughout four stages consisting of inserting, releasing, calibration, and springback. It is found that the inserting stage greatly reduces the dimensional deviations in a pure bending state, while the calibration stages further minimise the deviations in the bending and transverse stretching combined state. In addition, the wedge angle of the tool is found to be critical to the dimensional accuracy improvement. The low wedge angle facilitates the correction of sidewall inclination and gap opening, while the high wedge angle contributes to mitigating bottom convexity. The overall outcome of this study enhances the fundamental understanding of the effects of in-process stretching and local-bending on the dimensional capabilities of U-channel extrusions. This can ultimately generate guidelines that will lead to new application areas of aluminium extrusions in highly competitive marketplaces.
format	article
author	Xianyan Zhou Torgeir Welo Jun Ma Sigmund A. Tronvoll
author_facet	Xianyan Zhou Torgeir Welo Jun Ma Sigmund A. Tronvoll
author_sort	Xianyan Zhou
title	Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions
title_short	Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions
title_full	Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions
title_fullStr	Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions
title_full_unstemmed	Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions
title_sort	deformation characteristics in a stretch-based dimensional correction method for open, thin-walled extrusions
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/73988c885b0c42818c5294b67fe01a33
work_keys_str_mv	AT xianyanzhou deformationcharacteristicsinastretchbaseddimensionalcorrectionmethodforopenthinwalledextrusions AT torgeirwelo deformationcharacteristicsinastretchbaseddimensionalcorrectionmethodforopenthinwalledextrusions AT junma deformationcharacteristicsinastretchbaseddimensionalcorrectionmethodforopenthinwalledextrusions AT sigmundatronvoll deformationcharacteristicsinastretchbaseddimensionalcorrectionmethodforopenthinwalledextrusions
_version_	1718411266120220672

Deformation Characteristics in a Stretch-Based Dimensional Correction Method for Open, Thin-Walled Extrusions

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