Numerical simulation of edge effect in plasma arc forming of sheet metal
Edge effect was found in plasma arc forming process of sheet metal, which reduces the forming accuracy of sheet metal seriously. In order to reveal the forming mechanism and forming laws of the edge effect. A numerical model on forming of sheet metal using plasma arc with scanning along a straight line was established and the forming mechanism and forming laws of the edge effect were studied. The results showed that the upper material and the lower material of the edge were produced shrinkage along the scanning path and both shrinkage were different. The size relationship of the two shrinkage determines the direction of edge warp. The difference of the two shrinkage affects the warpage of the edge. In the comprehensive effect of shrinkage and warpage, the non scanning region in the both sides of the scanning path appears bulge or depression. The numerical analysis results were agree well with the experimental results. The conclusions provide a theoretical basis to reduce the effect of the edge effect on the accuracy of the sheet metal forming.
Analysis and Prediction of Edge Effects in Laser Bending
Laser forming of sheet metal offers the advantages of requiring no hard tooling and thus reduced cost and increased flexibility. It also enables forming of some materials and shapes that are not possible now. In single-axis laser bending of plates, the bending edge is found to be somewhat curved and the bending angle varies along the laser-scanning path. These phenomena are termed edge effects, which adversely affect the accuracy of the bending and result in undue residual stress. Numerical investigations are carried out to study the process transiency and the mechanism of the edge effects. Temperature dependency of material properties and strain-rate dependency of flow stress are considered in the numerical simulation to improve prediction accuracy. Numerical results are validated in experiments. Patterns of edge effects and resultant residual stress distributions are examined under a wide range of conditions. A more complete explanation for the mechanism of the edge effects is given.
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