A sustainability point of view on sheet metal forming operations: material wasting and energy consumption in incremental forming and stamping processes

2012 ◽  
Vol 29-30 ◽  
pp. 255-268 ◽  
Author(s):  
Giuseppe Ingarao ◽  
Giuseppina Ambrogio ◽  
Francesco Gagliardi ◽  
Rosa Di Lorenzo
Keyword(s):  
Energy Consumption ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Point Of View

On the Sustainability Evaluation in Sheet Metal Forming Processes

2011 ◽  
Vol 473 ◽  
pp. 824-829 ◽  
Author(s):  
Giuseppe Ingarao ◽  
Giuseppina Ambrogio ◽  
Rosanna Di Lorenzo ◽  
Fabrizio Micari
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Environmental Sustainability ◽  
Metal Forming ◽  
Incremental Forming ◽  
Point Of View ◽  
Sustainability Evaluation ◽  
Forming Process ◽  
Process Energy ◽  
Environmental Burdens

In sheet metal forming processes there is still a lack of knowledge in the field of environmental sustainability mainly due to the need of a proper modeling of issues and factors to be taken into account. Such topic is, nowadays, a urgent and remarkable issue in manufacturing and the main concerns are related to more efficient use of materials and energy. What is more, the estimation of environmental burdens of forming technologies is very complex to be accomplished since it is essentially process-dependent. This means that when comparing, for instance, a traditional forming process with an innovative one, there are some peculiar aspects to be considered; actually, processes can be rather different each other in terms of tooling, operative parameters and so on. In this paper, a first modeling effort is presented in order to compare, from a sustainability point of view, a classical stamping process with an incremental forming one. In particular, a frustum of pyramid part is considered and a quantitative analysis of the process energy consumption was developed. The paper aims to provide some sustainability guidelines to promote discussion on limitations, advantages, savings, drawbacks offered by different technologies within sheet metal forming field.

Experimental Study on Residual Formability of Single Point Incrementally Formed Part

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Conventional Process

Abstract A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

Formability and Surface Finish Studies in Single Point Incremental Forming

2011 ◽  
Author(s):  
A. Bhattacharya ◽  
Samarjit Singh ◽  
K. Maneesh ◽  
N. Venkata Reddy ◽  
Jian Cao
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Surface Finish ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Experimental Results ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming ◽  
Tool Diameter

Incremental sheet metal forming (ISMF) has demonstrated its great potential to form complex three-dimensional parts without using a component specific tooling. The die-less nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet parts. However, ISMF has limitations with respect to maximum formable wall angle, geometrical accuracy and surface finish of the component. In the present work, an experimental study is carried out to study the effect of incremental sheet metal forming process variables on maximum formable angle and surface finish. Box-Behnken method is used to design the experiments for formability study and full factorial method is used for surface finish study. Analysis of experimental results indicates that formability in incremental forming decreases with increase in tool diameter. Formable angle first increases and then decreases with incremental depth and it is also observed that the variation in the formable angle is not significant in the range of incremental depths considered to produce good surface finishes during the present study. A simple analysis model is used to estimate the stress values during incremental sheet metal forming assuming that the deformation occurs predominantly under plane strain condition. A stress based criterion is used along with the above mentioned analysis to predict the formability in ISMF and its predictions are in very good agreement with the experimental results. Surface roughness decreases with increase in tool diameter for all incremental depths. Surface roughness increases first with increase in incremental depth up to certain angle and then decreases. Surface roughness value decreases with increase in wall angle.

New Method for Blank Expansion of Rectangular Box

2011 ◽  
Vol 308-310 ◽  
pp. 1004-1007
Author(s):  
Liu Ru Zhou ◽  
Hai Ming Wan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Apex Angle ◽  
Forming Limit ◽  
Forming Process ◽  
Incremental Sheet Metal Forming ◽  
Planning Experiment

The principle of NC incremental sheet metal forming as well as the process planning, experiment of the square conical box forming are presented. Because the deformation of sheet metal only occurs around the tool head and the deformed region is subjected to stretch deformation and thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheet metal deformation. The sine law indicates that the thickness of the square conical box wall is close to zero when the half-apex angle of the square conical box wall is close to zero. Therefore, we must know the forming limit half-apex angle to ensure that the forming can be carried out successfully, i.e., to ensure that the deformed region with a certain thickness will not fracture. It will succeed in square conical box incremental forming in a single tool-path if the forming is carried out with an angle which is larger than the forming limit half-apex angle. The fracture in the forming component can be avoided by these methods. A square conical box of uniform wall-thickness can be formed by NC incremental forming process. The thickness of deformation area is increased by increasing half-apex angle. The wrinkle in the forming component can be avoided by these methods.

Incremental Forming: An Innovative Process for Small Batch Production

2012 ◽  
Vol 729 ◽  
pp. 85-90 ◽  
Author(s):  
Miklos Tisza ◽  
Péter Zoltán Kovács ◽  
Zsolt Lukács
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Main Process ◽  
Batch Production ◽  
General Overview ◽  
Process Characteristics ◽  
Innovative Process ◽  
Incremental Sheet Metal Forming

The need for flexible forming processes is of utmost importance in the recent years. Therefore, it is very important to develop new innovative technologies and processes. This is particularly valid for small batch and prototype production. Incremental sheet metal forming may be regarded as one of the promising developments for these purposes. In this paper, first a general overview of main process characteristics of the incremental sheet metal forming will be given. Then some recent results of a joint Eureka project launched by two universities and two SME companies in Hungary and Slovenia will be presented.

Compensations for Tool Path to Enhance Accuracy During Double Sided Incremental Forming

2015 ◽  
Author(s):  
Rakesh Lingam ◽  
Anirban Bhattacharya ◽  
Javed Asghar ◽  
N. Venkata Reddy
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Incremental Sheet Metal Forming

Incremental Sheet Metal Forming (ISMF) is a flexible sheet metal forming process that enables forming of complex three dimensional components by successive local deformations without using component specific tooling. ISMF is also regarded as die-less manufacturing process and in the absence of part-specific dies, geometric accuracy of formed components is inferior to that of their conventional counterparts. In Single Point Incremental Forming (SPIF), the simplest variant of ISMF, bending near component opening region is unavoidable due to lack of support. The bending in the component opening region can be reduced to a larger extent by another variant of ISMF namely Double Sided Incremental Forming (DSIF) in which a moving tool is used to support the sheet locally at the deformation zone. However the overall geometry of formed components still has unacceptable deviation from the desired geometry. Experimental observation and literature indicates that the supporting tool loses contact with the sheet after forming certain depth. Present work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflection due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap that occurs during forming (instead of using sine law). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths.

CAM-Solution for Two Robots Based Incremental Sheet Metal Forming

2011 ◽  
Vol 473 ◽  
pp. 889-896 ◽  
Author(s):  
D. Kreimeier ◽  
J. Zhu ◽  
V. Smukala ◽  
B. Buff ◽  
C. Magnus
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Industrial Robots ◽  
Forming Process ◽  
Lateral Direction ◽  
Incremental Sheet Metal Forming ◽  
Supporting Tool ◽  
Tool Building

Robot based incremental sheet metal forming (Roboforming)is a new dieless forming process, which is suitable for cost-effective manufacture of prototype parts and small batch sizes.The principle of Roboforming is based on flexible shaping through a freely programmable path-synchronous movement of two industrial robots. These two robots, which are connected to a cooperating robot system, hold respectively a forming and a supporting tool. Similar to other incremental forming methods, the final shape is produced bythe movement of the forming toolalongthe lateral direction and its gradual infeed in the depth direction. In Roboforming, there are twodifferent strategies for the synchronous movement of the supporting tool, eitheralong the outer contour onbacksideof the sheet or directly opposed to the forming tool building a forming gap.The second strategy can be combined with a force controlled method to increase the surface quality and geometricaccuracy. MThe most existing CAM systems used in numerous incremental forming approaches are only applicable for milling machines. In this paper, with the use of self-programmed postprocessors and an Application Programming Interface (API) in a CAM system, movement programs for two cooperating robots can be generated for both forming strategies to produce sheet metal parts with different sizes and complex freeform structures. This CAM-solution for Roboforming is validated bythe forming experiments.

Asymmetric Incremental Sheet Forming

2005 ◽  
Vol 6-8 ◽  
pp. 35-58 ◽  
Author(s):  
J. Jeswiet
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Localized Deformation ◽  
Recent Advances ◽  
Conventional Spinning ◽  
Forming Methods

The use of computers in manufacturing has enabled the development of several new sheet metal forming processes. This paper describes modifications that have been made to traditional forming methods such as conventional spinning and shear forming, where deformation is localized. Recent advances have enabled this localized deformation to be accurately controlled and studied. Current developments have been focused on forming asymmetric parts using CNC technology, without the need for costly dies. Asymmetric Incremental Forming has the potential to revolutionize sheet metal forming, making it accessible to all levels of manufacturing.

Formability and Surface Finish Studies in Single Point Incremental Forming

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
A. Bhattacharya ◽  
K. Maneesh ◽  
N. Venkata Reddy ◽  
Jian Cao
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Surface Finish ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Experimental Results ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming ◽  
Tool Diameter

Incremental sheet metal forming (ISMF) has demonstrated its great potential to form complex three-dimensional parts without using a component specific tooling. The die-less nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet parts. However, ISMF has limitations with respect to maximum formable wall angle, geometrical accuracy, and surface finish of the component. In the present work, an experimental study is carried out to study the effect of incremental sheet metal forming process variables on maximum formable angle and surface finish. Box–Behnken method is used to design the experiments for formability study and full factorial method is used for surface finish study. Analysis of experimental results indicates that formability in incremental forming decreases with increase in tool diameter. Formable angle first increases and then decreases with incremental depth and it is also observed that the variation in the formable angle is not significant in the range of incremental depths considered to produce good surface finishes during the present study. A simple analysis model is used to estimate the stress values during incremental sheet metal forming assuming that the deformation occurs predominantly under plane strain condition. A stress-based criterion is used along with the above mentioned analysis to predict the formability in ISMF and its predictions are in very good agreement with the experimental results. Surface roughness decreases with increase in tool diameter for all incremental depths. Surface roughness increases first with increase in incremental depth up to certain angle and then decreases. Surface roughness value decreases with increase in wall angle.

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