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Springer Tracts in Mechanical Engineering Series Editors Seung-Bok Choi, College of Engineering, Inha University, Incheon, Korea (Republic of) Haibin Duan, Beijing University of Aeronautics and Astronautics, Beijing, China Yili Fu, Harbin Institute of Technology, Harbin, China Carlos Guardiola, CMT-Motores Termicos, Polytechnic University of Valencia, Valencia, Spain Jian-Qiao Sun, University of California, Merced, CA, USA Young W. Kwon, Naval Postgraduate School, Monterey, CA, USA Francisco Cavas-Martínez , Departamento de Estructuras, Universidad Politécnica de Cartagena, Cartagena, Murcia, Spain Fakher Chaari, National School of Engineers of Sfax, Sfax, Tunisia Francesca di Mare, Institute of Energy Technology, Ruhr-Universität Bochum, Bochum, Nordrhein-Westfalen, Germany Hamid Reza Karimi, Department of Mechanical Engineering, Politecnico di Milano, Milan, Italy Springer Tracts in Mechanical Engineering (STME) publishes the latest develop- ments in Mechanical Engineering - quickly, informally and with high quality. 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Xunzhong Guo Editor Flexible Metal Forming Technologies Principles, Process and Equipment Editor Xunzhong Guo School of Materials Science and Technology Nanjing University of Aeronautics and Astronautics Nanjing, Jiangsu, China ISSN 2195-9862 ISSN 2195-9870 (electronic) Springer Tracts in Mechanical Engineering ISBN 978-981-19-1347-1 ISBN 978-981-19-1348-8 (eBook) https://doi.org/10.1007/978-981-19-1348-8 © The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022 This work is subject to copyright. All rights are solely and exclusively licensed by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors, and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, expressed or implied, with respect to the material contained herein or for any errors or omissions that may have been made. The publisher remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore Preface Flexible forming technologies are the methods of precise plastic forming of products by using flexible forming equipment and flexible tools and dies. The outstanding advantages of flexible forming technologies are strong and wide adaptability and low mold cost. Nowadays, many kinds of products in aerospace and different engineering applications are increasingly showing diversified and personalized rapid manufacturing requirements. The traditional manufacturing technologies, which depend on molds, have obvious limitations in terms of response speed and manufacturing cost. Using flexible forming technologies, it is easy to realize efficient manufacturing and intelligent manufacturing. Thus, it takes too much attention recently all over the world. Nevertheless, flexible forming technologies are carried out under less and uncon- strained conditions. The flow of the materials is relatively free, the shape and size of components are not easy to control, and there are various forms of defects. There- fore, flexible forming technologies face some difficulties in forming and controlling processes during manufacturing thin-walled complex-shaped components. Recently, related research and development institutions in China, Japan, Germany, the USA, and many other countries are engaged in the research and development of advanced flexible forming technologies. Notwithstanding, so far, there is still a lack of a systematic academic monograph on the flexible forming of complex metal components in the aspects of forming mechanism, formability control methods, material flow, equipment design, and configuration. The Flexible Forming Technologies and Equipment research group at Nanjing University of Aeronautics and Astronautics (NUAA) is the research team established based on the country’s major needs in aerospace and nuclear energy engineering. The flexible forming technologies research group has solid experience and outstanding results in designing and manufacturing flexible forming technologies such as flexible bending forming, incremental forming, spinning forming, and multi-point forming. Meantime, lots of researches on key technologies for process simulation optimization and defect control have been carried out. The research results of flexible forming technology have obtained critical engineering applications in the relevant engineering fields, such as aerospace, nuclear energy engineering, automobile, and petrochemical. v vi Preface In order to make the research results play a greater role, through carefully combing and summarizing in detail, this book entitled “Flexible metal forming technologies: Principles, process and equipment” has been done. The book is divided into nine chapters, and a quick preview of the contents is given as follows: Chapter 1 introduces the main direction of manufacturing technology innovation in recent years, analyzes the shortcomings of traditional manufacturing technology based on customer needs, expounds on the development status and latest research results of flexible forming technology in the field of metal products manufacturing, and summarizes the typical characteristics and development trend of flexible forming technology from the aspects of flexible forming equipment, process, and materials. Chapter 2 introduces the forming principle, the deformation mechanism during the incremental forming, the different variants of incremental forming, and the key forming process at different temperatures and different materials. Besides, the research progress of the incremental forming technology and equipment is also discussed. Chapter 3 introduces the forming principle, spinning equipment, and tooling design of the flexible spinning forming technology. Then starting from three processes of thin-wall and revolving body components of spinning forming, bimetallic composite tube of spinning forming, and power spinning of thin-walled components, through the combination of simulation and experiment, the flexible spinning forming technology is deeply discussed. Chapter 4 introduces the multi-point forming technology (MPF) in detail from the aspects of forming principle, shape adjustment mechanism, multi-point die system design, finite element simulation, and multi-point forming process of typical components. In addition, a multi-point rubber forming process has been developed by combining multi-point forming technology with rubber forming technology. Chapter 5 systematically introduces the principles of flexible forming technologies, the mechanism of forming and controlling process, the design and the configuration rules for flexible forming technologies, materials flow, and forming defects during the forming process. Furthermore, the current forming simulation and shape control solution in flexible roll forming are introduced. Finally, comprehensive summary and outlook of this technology are discussed. Chapter 6 introduces 3DQ technology which can realize the high-precision inte- gral forming of three-dimensional components with high-strength and complex features. Using the optimized robot trajectory and process parameters, 3DQ bending components with satisfactory shape and performance can be formed. Chapter 7 introduces the 3D free bending forming technology of 3D complex hollow components. Firstly, it introduces the classification of three-dimensional free bending equipment and analyzes the principles of three-axis free bending, six-axis free bending and free bending based on parallel mechanism, analysis of forming trajectory algorithm, and the structure of key molds. Finally, the concept of warm free bending is proposed for the difficult-to-deform titanium alloy pipe, and the feasibility of the process is verified by finite element simulation and experiment. Preface vii Chapter 8 introduces the flexible roll forming technology of complex profile bending components. Starting from the principle of roll forming, the trajectory analysis of roll forming and the principle of mold design are introduced. And through the finite element simulation and experiment, the wall thickness distribution law, the axis dimension accuracy of the plane and three-dimensional roll bending of aluminum alloy rectangular tube are studied, respectively, which provides technical guidance for the actual production and processing. Chapter 9 introduces a new type of tube die less forming technology called “Flex- ible tube die less forming”, using heating equipment or forming tool to replace the constraint of forming die on the tube, so as to make the material deform according to the preset requirements and realize the die less forming of tube. Due to this feature, flexible tube die less forming is suitable for flexible forming of some tubes with complex, irregular, or even regular-changing cross-section shapes. This book introduces the principles of flexible forming technologies to manu- facture thin-walled complex-shaped components, the mechanism of controlling the material flow, and the design and the configuration of flexible forming technologies’ equipments and tools systematically. The relevant content will play a significant guiding role for researchers, engineers, and graduate and undergraduate students; hence, the book has a good market prospect. Gratefully appreciate your interest and the time taken to read this book entitled “Flexible metal forming technologies: Principles, process and equipment” and hope it is worthwhile to add some unique opinions to this rapidly developing flexible metal forming technology. Nanjing, China Prof. Dr. Xunzhong Guo 2021 Acknowledgments First of all, I gratefully appreciate the financial support from the National Natural Science Foundation of China (Projects Nos. U1937206, 52175328, 52105362, 52105360, 51711540301, 51205196 and 5201101342), Jiangsu Province Key Research and Development Project (No. BE2019007-2), the Aeronautical Science Foundation of China (Project No. 2016ZE52047), the Natural Science Foundation of Jiangsu Province (Project No. BK20151469, BK20210310, BK20200453), the Qing Lan Project, Jiangsu Provincial Department of Education, China, Opening Project of Jiangsu Key Laboratory of Advanced Structural Materials and Applica- tion Technology (No. ASMA201903), Opening Project of State Key Lab of Digital Manufacturing Equipment & Technology (No. DMETKF2021004), and the Funda- mental Research Funds for the Central Universities (Projects Nos. NT2020015 and NS2021046), who supported my research work on flexible forming technologies. I appreciate my Ph.D. supervisors Prof. Jie Tao who gave me very serious teaching and support. I appreciate the members of flexible forming group: Senior Researcher Yizhou Shen, Associate Professor Huaguan Li, Lecturer Hui Wang, Lecturer Cheng Cheng, Lecturer Chunmei Liu, Assistant Miss Gui Wei, and Research Associate Dr. Ali Abd El-Aty for their help and support on flexible forming. I also appreciate Prof. Albert Sedlmaier of data M Sheet Metal Solutions GmbH in Germany, Dr. Yong Sun of the Ultra-X Lab of Shenzhen Institute for Advanced Study of University of Electronic Science and Technology of China, and Xiaohong Zheng of Guangdong Gaopu Bending Technology Co. Ltd. and Guangdong Bosai CNC Machine Tool Co. Ltd. that contributed a lot to the better understanding of flexible forming technologies. Furthermore, I wish to thank my Ph.D. and M.D. students, Mr. Qiucheng Yang, Mr. Shenghan Hu, Mr. Shuo Zheng, Mr. Cong Wu, Mr. Zushu Huang, Mr. Hao Zhang, Mr. Jiaxin Guo, Mr. Zijie Wang, Mr. Chao Pan, Mr. Zhenbiao Sun, Mr. Haoran Luo, Mr. Shixuan Liu, Miss. Wenfeng Guo, Mr. Yangyang Deng, Mr. Haoqi Ni, Mr. Rensixu Zhang, and Mr. Shaoxin Li for their serious diligent work for our research projects. Many of the results as presented in this book actually have been achieved together with my colleagues and students. ix x Acknowledgments I also gratefully acknowledge the copyright permission from the following publishers including Springer, Elsevier, Maney Publishing, IOP Publishing, and AIP Publishing for the reproduction of the author’s published journal papers. In particular, I wish to thank my wife Wei Yan for her encouragement and support for my scientific research. At the same time, I would like to thank my son Yihang and daughter Yining. After work every day, their welcome and hug swept away my fatigue. All of them are an important driving force for me to engage in scientific research of flexible forming technology.