Forming Limit Predictions for the Serrated Strain Paths in Single Point Incremental Sheet Forming

2007 ◽  
Author(s):  
P. Eyckens ◽  
S. He ◽  
A. Van Bael ◽  
P. Van Houtte ◽  
J. Duflou
Keyword(s):  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Limit ◽  
Strain Paths

Multiobjective optimization of process variables in single-point incremental forming using grey relational analysis coupled with entropy weights

2021 ◽  
pp. 146442072110204
Author(s):  
Abdulmajeed Dabwan ◽  
Adham E Ragab ◽  
Mohamed A Saleh ◽  
Atef M Ghaleb ◽  
Mohamed Z Ramadan ◽  
...  
Keyword(s):  
Grey Relational Analysis ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Process Variables ◽  
Relational Analysis ◽  
Grey Relational

Incremental sheet forming is a specific group of sheet forming methods that enable the manufacture of complex parts utilizing computer numerical control instead of specialized tools. It is an incredibly adaptable operation that involves minimal usage of sophisticated tools, dies, and forming presses. Besides its main application in the field of rapid prototyping, incremental sheet forming processes can be used for the manufacture of unique parts in small batches. The goal of this study is to broaden the knowledge of the deformation process in single-point incremental forming. This work studies the deformation behavior in single-point incremental forming by experimentally investigating the principal stresses, principal strains, and thinning of single-point incremental forming products. Conical-shaped components are fabricated using AA1050-H14 aluminum alloy at various combinations of fundamental variables. The factorial design is employed to plan the experimental study and analysis of variance is conducted to analyze the results. The grey relational analysis approach coupled with entropy weights is also implemented to identify optimum process variables for single-point incremental forming. The results show that the tool diameter has the greatest effect on the thinning of the SPIF product, followed by the sheet thickness, step size, and feed rate.

Experimental and Numerical Analysis of Forming Limits in CNC Incremental Sheet Forming

2007 ◽  
Vol 344 ◽  
pp. 511-518 ◽  
Author(s):  
Markus Bambach ◽  
M. Todorova ◽  
Gerhard Hirt
Keyword(s):  
Sheet Metal ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Negative Slope ◽  
Evaluation Procedure ◽  
Forming Limit ◽  
Limit Curve ◽  
Forming Limit Curve ◽  
Forming Limits ◽  
Straight Line

Asymmetric incremental sheet forming (AISF) is a relatively new manufacturing process for the production of low volumes of sheet metal parts. Forming is accomplished by the CNC controlled movements of a simple ball-headed tool that follows a 3D trajectory to gradually shape the sheet metal blank. Due to the local plastic deformation under the tool, there is almost no draw-in from the flange region to avoid thinning in the forming zone. As a consequence, sheet thinning limits the amount of bearable deformation, and thus the range of possible applications. Much attention has been given to the maximum strains that can be attained in AISF. Several authors have found that the forming limits are considerably higher than those obtained using a Nakazima test and that the forming limit curve is approximately a straight line (mostly having a slope of -1) in the stretching region of the FLD. Based on these findings they conclude that the “conventional” forming limit curves cannot be used for AISF and propose dedicated tests to record forming limit diagrams for AISF. Up to now, there is no standardised test and no evaluation procedure for the determination of FLCs for AISF. In the present paper, we start with an analysis of the range of strain states and strain paths that are covered by the various tests that can be found in the literature. This is accomplished by means of on-line deformation measurements using a stereovision system. From these measurements, necking and fracture limits are derived. It is found that the fracture limits can be described consistently by a straight line with negative slope. The necking limits seem to be highly dependent on the test shapes and forming parameters. It is concluded that standardisation in both testing conditions and the evaluation procedures is necessary, and that a forming limit curve does not seem to be an appropriate tool to predict the feasibility of a given part design.

Parameter optimization and texture evolution in single point incremental sheet forming process

2019 ◽  
Vol 234 (1-2) ◽  
pp. 126-139 ◽  
Author(s):  
Shamik Basak ◽  
K Sajun Prasad ◽  
Amarjeet Mehto ◽  
Joy Bagchi ◽  
Y Shiva Ganesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Regression Models ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Input Process ◽  
Truncated Cone

Prototyping through incremental sheet forming is emerging as a latest trend in the manufacturing industries for fabricating personalized components according to customer requirement. In this study, a laboratory scale single-point incremental forming test setup was designed and fabricated to deform AA6061 sheet metal plastically. In addition, response surface methodology with Box–Behnken design technique was used to establish different regression models correlating input process parameters with mechanical responses such as angle of failure, part depth per unit time and surface roughness. Correspondingly, the regression models were implemented to optimize the input process parameters, and the predicted responses were successfully validated at the optimal conditions. It was observed that the predicted absolute error for angle of failure, part depth per unit time and surface roughness responses was approximately 0.9%, 4.4% and 6.3%, respectively, for the optimum parametric combination. Furthermore, the post-deformation responses from an optimized single point incremental forming truncated cone were correlated with microstructural evolution. It was observed that the peak hardness and highest areal surface roughness of 158 ± 9 HV and 1.943 μm, respectively, were found near to the pole of single-point incremental forming truncated cone, and the highest major plastic strain at this region was 0.80. During incremental forming, a significant increase in microhardness occurred due to grain refinement, whereas a substantial increase in the Brass and S texture component was responsible for the increase in the surface roughness.

Incremental Sheet Forming with an Industrial Robot – Forming Limits and Their Effect on Component Design

2005 ◽  
Vol 6-8 ◽  
pp. 457-464 ◽  
Author(s):  
L. Lamminen
Keyword(s):  
Sheet Metal ◽  
Industrial Robot ◽  
Forming Limit Diagram ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Point Of View ◽  
Forming Limit ◽  
Forming Process ◽  
3D Cad ◽  
Component Design

Incremental sheet forming (ISF) has been a subject of research for many research groups before. However, all of the published results so far have been related to either commercial ISF machines or ISF forming with NC mills or similar. The research reported in this paper concentrates on incremental sheet forming with an industrial robot. The test equipment is based on a strong arm robot and a moving forming table, where a sheet metal blank is attached. The tool slides on the surface of the sheet and forms it incrementally to the desired shape. The robot is capable of 5-axis forming, which enables forming of inwards curved forms. In this paper the forming limit diagram (FLD) for ISF with the robot is presented and it is compared with conventional forming limit diagrams. It will be shown that the conventional FLD does not apply to incremental forming process. Geometrical accuracy of sample pieces is also studied. Cones of different shapes are formed with the robot equipment and their correspondence with the 3D CAD model is evaluated. The results are compared with other results of accuracy of incremental sheet forming, reported earlier by other researchers. The third issue covered in this article is a product development point of view to incremental sheet forming. In addition to fast prototyping and low volume production of sheet metal parts, ISF brings new possibilities to sheet metal component design and manufacturing. These possibilities can only be exploited if design rules, that will take the possibilities and limitations of the method into account are created for ISF.

scholarly journals Cranial Reconstruction Using Double Side Incremental Forming

2015 ◽  
Vol 639 ◽  
pp. 535-542 ◽  
Author(s):  
Bin Lu ◽  
Dong Kai Xu ◽  
Run Zhe Liu ◽  
Heng An Ou ◽  
Hui Long ◽  
...  
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Pure Titanium ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Backing Plate ◽  
Cranial Implant

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Comparing to conventional sheet forming processes, ISF is of a clear advantage in manufacturing small batch or customized products such as cranial implant. Although effort on cranial reconstruction by using incremental sheet forming approach has been made in recent years, research has been mostly based on the single point incremental forming (SPIF) strategy and there are still considerable technical challenges for achieving better geometric accuracy, thickness distribution and complex cranial shape. In addition, the use of a backing plate or supporting die reduces the process flexibility and increases the cost. To overcome these limitations, double side incremental sheet forming (DSIF) process is employed for forming Grade 1 pure titanium sheet by using different toolpath strategies. The geometric accuracy and thickness distribution of the final part are evaluated so the optimized tool path strategies are developed. This leads to an assessment of the DSIF based approach for the application in cranial reconstruction.

Brass 70/30 and Incremental Sheet Forming Process

2013 ◽  
Vol 554-557 ◽  
pp. 1419-1431 ◽  
Author(s):  
Daniel Fritzen ◽  
Anderson Daleffe ◽  
Jovani Castelan ◽  
Lirio Schaeffer
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Cnc Machining ◽  
Forming Process ◽  
Wall Angle ◽  
Machining Center ◽  
Cad Cam ◽  
Cnc Machining Center

This work addresses through bibliographies and experiments the behavior of sheet brass 70/30 for Incremental Sheet Forming process - ISF, based on the parameters: wall angle (), step vertical (ΔZ) strategy and the way the tool. Experiments based on the method called Single Point Incremental Forming - SPIF. For execution of practical tests, we used the resources: software CAD / CAM, CNC machining center with three axles, matrix incremental, incremental forming tool and a device press sheets. Furthermore, measurement was made of the true deformation () and thickness (s1). Practical tests have shown that the spiral machining strategy yielded a greater wall angle, compared to the conventional strategy outline.

scholarly journals A Novel Tool to Enhance The Lubricant Efficiency On Induction Heat-Assisted Incremental Sheet Forming of Ti-6Al-4V Sheets

2022 ◽  
Author(s):  
Weining Li ◽  
Khamis Essa ◽  
Sheng Li
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Water Channel ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Water Cooling ◽  
Geometric Accuracy ◽  
Molybdenum Disulphide ◽  
Roughness Analysis ◽  
Pass Through

Abstract For heat-assisted single point incremental sheet forming (SPIF) works of Ti-6Al-4V sheets, the use of lubricant has shown significant effects on surface quality and geometric accuracy at higher temperatures. Molybdenum disulphide (MoS2) is a common lubricant widely used in SPIF works, however, it usually indicates ineffective performance at high temperatures. This article has studied different lubricants of MoS2 lubricants and proposed a novel mixture of MoS2 to provide better surface quality and improve geometric accuracy. A forming tool with a ball-roller and water channel was designed to enable the MoS2 mixture to pass through the tool tip, allowing easy application of the lubricant on the localised area and reduce the thermal expansion on the ball-roller. Surface roughness analysis has revealed that the water-cooling MoS2 mixture performed well in reducing friction effects and achieved better geometric accuracy. Forming forces measurements, scanning electron microscope (SEM), energy dispersive X-ray Analysis (EDX) and micro-hardness tests also indicated that a higher strain hardening behaviour was detected for the water-cooling MoS2 mixture.

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