Study of the Effect of Process Parameters and Optimization of Bending Angle in Laser Bending

Document Type : Original Article

Authors

Faculty of Mechanical Engineering, Babol Noshirvani University of Technology, Babol, Iran

Abstract

The laser forming process is an emerging area of research and industry, primarily focused on materials like titanium, magnesium, steel, and their alloys. However, aluminum alloys have received less attention due to challenges related to surface reflection and low absorption coefficients.

In this research, the effect of different process parameters on bending angle in the laser bending of Al 6061 sheets was investigated by experiments and finite element simulation. The parameters were optimized by Response Surface Method (RSM) to achieve the maximum bending angle. In addition, the reproducibility of the process, as well as the accuracy and validation of the simulation, were examined by conducting experiments that involved accurate measurement of the bending angle. The results revealed that the sheet thickness had the most significant effect on the bending angle. Specifically, with an increase of 1 mm in the sheet thickness, the bending angle decreased by 77%. Additionally, through process parameter optimization, the maximum bending angle achieved was 4.911 degrees.

Keywords

Main Subjects


[1] M. Geiger, F. Vollertsen, and G. Deinzer, "Flexible straightening of car body shells by laser forming", SAE Technical Paper, 1993. https://doi.org/10.4271/930279
[3] W. Shichun, and Z. Jinsong, "An experimental study of laser bending for sheet metals", Journal of Materials Processing Technology, vol. 110, no. 2, pp. 160-163, 2001. https://doi.org/10.1016/S0924-0136(00)00860-8
[4] Z. Hu, R. Kovacevic, and M. Labudovic, "Experimental and numerical modeling of buckling instability of laser sheet forming", International Journal of Machine Tools and Manufacture, vol. 42, no. 13, pp. 1427-1439, 2002. https://doi.org/10.1016/S0890-6955(02)00075-5
[6] M. Geiger, and F. Vollertsen, "The mechanisms of laser forming", CIRP Annals, vol. 42, no. 1, pp. 301-304, 1993. https://doi.org/10.1016/S0007-8506(07)62448-2
[7] Y. Namba, "Laser forming in space", in: Proceedings of the International Conference on Lasers' 85, Las Vegas, NV; 2-6 Dec, pp. 403-407, 1986.
[8] M. Riahi, M. Hoseinpour Gollo, and S. Nader Ameli Kalkhoran, "Experimental and numerical study of heat flux distribution in laser forming of bi-layer sheets", Journal of Computational & Applied Research in Mechanical Engineering (JCARME), vol. 4, no. 1, pp. 67-79, 2014. https://doi.org/10.22061/jcarme.2014.73
[12] S. Mulay, V. Paliwal, and N. R. Babu, "Analytical approach to predict the bend angle of sheet formed by multiple laser scans", Procedia CIRP, vol. 99, pp. 272-277, 2021. https://doi.org/10.1016/j.procir.2021.03.040
[15] K. Venkadeshwaran, S. Das, and D. Misra, "Bend angle prediction and parameter optimisation for laser bending of stainless steel using FEM and RSM", International Journal of Mechatronics and Manufacturing Systems, vol. 5, no. 3-4, no. 3-4, pp. 308-321, 2021. https://doi.org/10.1504/IJMMS.2012.048237
[16] E. G. Zahrani, and A. Marasi, "Modeling and optimization of laser bending parameters via response surface methodology", Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, vol. 227, no. 7, pp. 1577-1584, 2013. https://doi.org/10.1177/0954406212461119
[18] A. H. Roohia, H. Moslemi Naeini, M. Hoseinpour Gollo, J. Shahbazai Karimi, and Sh. Imani shahabad, "Effects of temperature gradient magnitude on bending angle in laser forming process of aluminium alloy sheets", Journal of Computational and Applied Research in Mechanical Engineering (JCARME), vol. 5, no. 2, pp. 97-109, 2016. https://doi.org/10.22061/jcarme.2016.423
[19] S. E. Khandandel, S. M. H, Seyedkashi, and M. Moradi, "A novel path strategy design for precise 2D and 3D laser tube forming process; experimental and numerical investigation", Optik, vol. 206, pp. 164302, 2020. https://doi.org/10.1016/j.ijleo.2020.164302
[20] S. E. Khandandel, S. M. H. Seyedkashi and M. Moradi, "Numerical and experimental analysis of the effect of forced cooling on laser tube forming", Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 43, no. 7, pp. 338, 2021. https://doi.org/10.1007/s40430-021-03063-9
[22] J. Zimmerman, W. Wlosinski, and Z. R. Lindemann, "Thermo-mechanical and diffusion modelling in the process of ceramic–metal friction welding", Journal of Materials Processing Technology, vol. 209, no. 4, pp. 1644-1653, 2009. https://doi.org/10.1016/j.jmatprotec.2008.04.012
 
 
CAPTCHA Image