Formability Investigation of a Thin-wall Part of Double Curvature Using an Integrated Reverse Engineering Environment

An integrated reverse engineering (RE) environment composed of modeling, forming simulation, tooling design and manufacturing, and forming operation was employed to solve an existing problem, in which a thin-wall part of double curvature was not able to be physically formed without tearing and wrinkle after numerous attempts at a logistics center. This paper focuses on the formability study of this challenging part using the newly established RE environment. Forming simulation was heavily employed to explore a narrow window that ensures a successful part forming by investigating blank shape design and understanding the material flow in forming. A key factor that ensures a successful part without tearing or wrinkle was clearly suggested by forming simulations. A physical forming process that incorporates such a factor was implemented at shop floor, which produced an accurate part without tearing and wrinkle for the first time after numerous attempts. Lessons learned are presented and the feasibility of bringing simulation to the shop floor at the logistics center is discussed.