Abstract
Aluminum profiles are increasingly used in the manufacture of lightweight components for electric vehicles. Stretch forming is a key operation for producing extrusion-based components, owing to its volume production capabilities. However, traditional stretch forming is characterized by limited flexibility and high tooling costs, which makes it less attractive in today’s dynamic market demanding rapid adaptation solutions.
In this research, a new 3D reconfigurable multi-piece tooling for a recently developed novel flexible stretch forming process was proposed to improve the flexibility. The new tooling concept is realized by dividing the unified 3D die into multiple adjustable pieces. Each unit includes an adjustable “bottom holder” and an adjustable “L-shape” bracket insert with a curved surface installed on the bottom holder. By controlling the positions of the array of L-shape brackets and holders, a wide range of reconfigurable tooling curvatures can be achieved for customized 3D forming. Using rectangular, hollow AA6082 profiles in T4 temper, the new tooling strategy has been verified, demonstrating its good capability for producing different part configurations. Looking forward, this reconfigurable tooling concept has demonstrated great potential in terms of dimensional accuracy and springback compensation in stretch forming, enabling customized, cost-effective, and rapid development of aluminum extrusion components.
