Research on Discrete Clamp Motion Path Control-Based Stretch-Forming Method for Large Surfaces

In this paper, a near-net discrete clamp motion path control (SF-CMPC)-based stretch-forming method is proposed as a solution for the low-cost high-quality machining of highly curved surfaces. In this approach, the clamps are discretized, the motion paths are designed to control deformation distribution and avoid forming defects, the stretch-forming transition zone can be effectively reduced, the material utilization rate can be increased, and the near-net formation of large surfaces can be achieved. To investigate this method’s feasibility, the conventional stretch-forming (SF-C) and SF-CMPC processes are numerically analyzed. The results indicate that, upon increasing the transition zone length via SF-CMPC, the maximum thickness reduction and strain value are reduced by 0.010 mm and 0.0249, respectively, with the dependence of the forming quality on the transition zone length being significantly reduced compared to SF-C. In the formation of surfaces with large curvatures, SF-CMPC’s crack risk is lower than SF-C’s crack risk, with better adaptability. Through controlling the contact process with a die, the sheet metals’ constraint state is improved, the transverse compressive strain can be effectively reduced via friction, and the wrinkling defects can be suppressed. A stretch-forming experiment was carried out on a spherical surface, using self-developed equipment. The feasibility of achieving surfaces’ near-net stretch forming by controlling the clamps’ motion paths was hereby proven.