Design and Implementation of a Versatile Flexible 3D Wire Bending Machine with Accuracy Algorithm

• Autorzy: Farhan Mohammed O. , Al-Khafaji Muhannad M.H. , Abood Muhannad Q.

Identyfikatory

DOI

10.12913/22998624/180310

• Języki publikacji: EN

Abstrakty

EN

This Paper presents the development of a flexible wire bending machine designed to overcome limitations associated with traditional counterparts. Traditionally, wire bending machines are often designed for specific purposes, necessitate complex coding, are prohibitively expensive, or are constrained to producing two-dimensional shapes. To address these challenges, our study begins with an extensive review of existing research in the field, followed by the selection of a concept derived from this analysis. The methodology encompasses the entire design and manufacturing process. Initial research guides the concept selection, which is then translated into a practical design using SolidWorks simulations. The theoretical foundation involves mathematical formulations for each machine component, ranging from the wire feeding system to the bidirectional and 3D bending mechanisms. Main actuators are chosen based on calculated parameters, and the machine is assembled, incorporating a CNC system. The machine is tested first without wire and subsequently with the bending of an aluminum (1350-H26), 3.2mm diameter wire, copper with 3.25 mm diameter and steel with 2.5 mm diameter. The Results demonstrate high accuracy performance and underscore the significance of considering spring back and bend allowance for precision in both 2D and 3D wire configurations. This study not only contributes to the design and fabrication of a flexible wire bending machine but also addresses the shortcomings of traditional counterparts, making wire bending more accessible, versatile, and cost-effective.

Słowa kluczowe

EN

wire bending; CNC; springback; bend allowance

• Wydawca: Lublin University of Technology ; Polish Society of Ecological Engineering (PTIE), Branch of PTIE in Lublin
• Czasopismo: Advances in Science and Technology. Research Journal
• Rocznik: 2024
• Tom: Vol. 18, no 1
• Strony: 244--254
• Opis fizyczny: Bibliogr., 8 poz., fig., tab.

Twórcy

autor

Farhan Mohammed O.

• Production Engineering and Metallurgy Department, University of Technology, Baghdad, Iraq

autor

Al-Khafaji Muhannad M.H.

• Production Engineering and Metallurgy Department, University of Technology, Baghdad, Iraq

• https://orcid.org/0000-0002-9307-0029

autor

Abood Muhannad Q.

• Production Engineering and Metallurgy Department, University of Technology, Baghdad, Iraq

Bibliografia

• 1. Shah A.K., Kumar N., Vignesh M., Khanna P. Design and fabrication of automatic rebar bending machine. 2018 Int. Conf. Comput. Power Commun. Technol. GUCON’2018. 2019; 1010–1013.
• 2. Murata M., Kuboki T. CNC tube forming method formanufacturing flexibly and 3-dimensionally bent tubes. Springer-Verlag Berlin Heidelb 2015.
• 3. Lavrič H., Bugeza M., Fiser R. Novel approach to closed-loop control of wire bending machine. Proc. Int. Conf. Power Electron. Drive Syst. 2011; Dec.: 1100–1105.
• 4. Tang W.X., Zhu H., Zhu M.X., Li Q.F., Zhang J. Research on key technology of wire-bending and equipment development. Manag. Sci. Eng. 2016; 10(1): 14–20. Available from: www.cscanada.netwww.cscanada.orgurl:http://www.cscanada.net/index.php/mse/article/view/8212DOI:http://dx.doi.org/10.3968/8212
• 5. Liu R., Wan W., Isomura E., Harada K. Metal wire manipulation planning for 3D curving - A low payload robot that uses a bending machine to bend high-stiffness wire. IEEE Int. Conf. Intell Robot Syst. 2022; Oct.: 8926–8931.
• 6. Abd El-Aty A., Guo X., Lee MG, Tao J, Hou Y, Hu S, et al. A review on flexibility of free bending forming technology for manufacturing thin-walled complex-shaped metallic tubes. Int. J. Light Mater. Manuf. 2023; 6(2): 165–188. https://doi.org/10.1016/j.ijlmm.2022.09.007
• 7. Gaspar M., Silva FJG, Pinto AG, Campilho RDSG. 2D and 3D wires formability for car seats: A novel full-automatic equipment concept towards high productivity and flexibility. Machines. 2023; 11(3).
• 8. Goto H., Ichiryu K., Saito H., Ishikura Y., Tanaka Y. Applications with a new 6-dof bending machine in tube forming processes. Proc. JFPS Int. Symp. Fluid Power. 2008; (7–1): 183–188.

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024).