Forming of Aluminium and Titanium Panel Parts with a Flexible Multi-Points-Tool Forming Technique

Multi-points-tool forming (MPF) is one of the special categories of sheet metal forming techniques with good operational flexibilities due to using two sets of adjustable pins along the machine-ram direction (vertical direction usually), which represent the acting points of desired forming-tool surface contours. The heights of the pins can be adjusted either in-press or off the press in order to change a representing, assembled die-surface contour, if the formed part geometry is to be changed. A main merit of such a technique is flexibility of tool setting to achieve different, representing forming-die surface contours without need to provide solid dies for the die-profiles for shaping, and hence, reducing operational time, labour cost, most importantly, tooling cost, which, in some cases, costs million pounds. The MPF is particularly suitable for small batch production for highly customized sheet-metal parts.

The aim of the proposed PhD project is to address quality control issues, as described above, in order to deliver a fundamental understanding as well as a process and tool design solution for the problems identified.

The objectives are to conduct fundamental research on the multi-points-tool forming, concerning material deformation mechanisms (during both loading and unloading process) and tool deflections, including stress and strain states and their effects on the sheet-metal springback when unloading occurs with multi-pins in actions. Interactions with the cushions will also be investigated. Based on which tool-design, workpiece holding, cushion designs will be re-designed/optimised to reduce or eliminate the two types of the defects identified for the forming of Aluminium and Tantinium thin sheet metals. The parts finding frequent uses will be tested, such as that used in aircrafts, building, home appliances/furniture and art-sculptures.