Application and correction of L-shaped thin-wall aluminum in flexible-bending processing

The new flexible-bending technique is used in three-dimension (3D) bending of profile and tube cross-sections. The bending radius of the forming part of profile or tube is adjusted by numerical control. The flexible-bending has some advantages, such as free definable bending geometry, and avoidance of re-clamping. The rapid development of Chinese aerospace industry has raised the demand for 3D bending profile. However, traditional bending methods of profile fail to meet the requirements of high applicability, and personalized small batch production. In this article, we studied the flexible-bending formability of asymmetric cross-section L-shaped thin-wall aluminum. The simulating calculation was carried out on finite element simulation software. Comparisons between simulation and experiment show that error analysis is needed. After the investigation of forming springback, side bending and twisting, we conclude that the springback amount changes to some extent following the increase of uplift amount H of bending die in the Y-direction. The springback can be optimized according to the variation trend. The side bending is eliminated by increasing the reverse displacement of the side bending trend. The twisting defect is relieved by intensifying the reverse displacement along the X-axis and altering degree-of-freedom UR3 along the Z-axis.