Investigation of Parametric Effects on Geometrical Inaccuracies in Deformation Machining Process

2018 ◽  
Vol 140 (7) ◽  
Author(s):  
Arshpreet Singh ◽  
Anupam Agrawal
Keyword(s):  
Incremental Forming ◽  
Numerical Study ◽  
Single Point ◽  
Machining Process ◽  
Complex Structures ◽  
Wide Range ◽  
Quality Product ◽  
Thin Structure ◽  
Parametric Effects ◽  
Manufacturing Techniques

Deformation machining (DM) is a combination of thin structure machining and single-point incremental forming/bending (SPIF/SPIB). This process enables the creation of complex structures and geometries, which are probably difficult or sometimes impossible to manufacture employing conventional manufacturing techniques. Geometrical discrepancies in thin structure or sheet metal bending and forming are a major obstacle in manufacturing quality components. These discrepancies are more prevalent and complex in nature in incremental or generative manufacturing. In the present work, a comprehensive experimental and numerical study on the parametric effects on various geometrical inaccuracies in DM process has been performed. This study would help in giving an insight in providing necessary geometrical compensation, ensuring a quality product over a wide range of process parameters.

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

scholarly journals Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 6794
Author(s):  
Zhou Yan ◽  
Hany Hassanin ◽  
Mahmoud Ahmed El-Sayed ◽  
Hossam Mohamed Eldessouky ◽  
Joy Rizki Pangestu Djuansjah ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Processing Time ◽  
Incremental Forming ◽  
Single Point ◽  
Computational Time ◽  
Single Point Incremental Forming ◽  
Two Stage ◽  
Element Analysis ◽  
Wide Range

Single-point incremental forming (SPIF) is a flexible technology that can form a wide range of sheet metal products without the need for using punch and die sets. As a relatively cheap and die-less process, this technology is preferable for small and medium customised production. However, the SPIF technology has drawbacks, such as the geometrical inaccuracy and the thickness uniformity of the shaped part. This research aims to optimise the formed part geometric accuracy and reduce the processing time of a two-stage forming strategy of SPIF. Finite element analysis (FEA) was initially used and validated using experimental literature data. Furthermore, the design of experiments (DoE) statistical approach was used to optimise the proposed two-stage SPIF technique. The mass scaling technique was applied during the finite element analysis to minimise the computational time. The results showed that the step size during forming stage two significantly affected the geometrical accuracy of the part, whereas the forming depth during stage one was insignificant to the part quality. It was also revealed that the geometrical improvement had taken place along the base and the wall regions. However, the areas near the clamp system showed minor improvements. The optimised two-stage strategy successfully decreased both the geometrical inaccuracy and processing time. After optimisation, the average values of the geometrical deviation and forming time were reduced by 25% and 55.56%, respectively.

Multiobjective Optimization of Single Point Incremental Forming: Comparison between Isotropic and Combined Hardening Behavior

2014 ◽  
Vol 611-612 ◽  
pp. 1031-1038 ◽  
Author(s):  
Henia Arfa ◽  
Riadh Bahloul ◽  
Hedi Belhadjsalah
Keyword(s):  
Process Parameters ◽  
Incremental Forming ◽  
Numerical Study ◽  
Kinematic Hardening ◽  
Thickness Distribution ◽  
Single Point ◽  
Surface Model ◽  
Mechanical Resistance ◽  
Single Point Incremental Forming ◽  
Incremental Step

Single point incremental forming (SPIF) of sheet metal is a promising process to produce small batch production and prototyping. This process consists of a controlled process of displacement performed on a three-axis CNC milling machine. In former work, the most critical factors which affected single point incremental forming process were found to be formed shape, tool size, material type, material thickness and incremental step size. The present work is focused on an optimization strategy of (SPIF) process determined by a numerical study based on finite element analyses (FEA) according to a Box-Behnken Design of Experiments. Two types of hardening behaviour laws of material are used: isotropic and combined isotropic-kinematic hardening behaviour. To do so, a set of numerical simulations are carried out for an aluminum truncated cone as geometry of a benchmark model. The simulation results include some decisions about the mechanical resistance and geometrical quality of the parts such as the thickness distribution and the magnitude of springback. In this paper, the main objective is to present an overview of multiobjective design optimization of process parameters in single point incremental forming operation in order to minimize the sheet thinning rate and the springback simultaneously. In this investigation, the steps of optimization procedure include the using of Box-Behnken experimental design for sample producing, response surface model for coarse fitting and a developed Multiobjective Genetic Algorithm (MOGA) for exact solving of fitness functions. The results show that these methods are able to determine all the best possible compromise with respect several antagonistic objectives as well as generate the approximate Pareto optimal solutions. So these will make it possible to choose the appropriate process parameters according to the objectives functions to be minimized and consequently the improvement of the products formed by the process of incremental forming.

scholarly journals Numerical study on the thickness homogenization in hole-flanging by single-point incremental forming

2018 ◽  
Vol 1063 ◽  
pp. 012183 ◽  
Author(s):  
D Morales-Palma ◽  
M Borrego ◽  
A J Martínez-Donaire ◽  
J A López-Fernández ◽  
G Centeno ◽  
...  
Keyword(s):  
Incremental Forming ◽  
Numerical Study ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Hole Flanging

scholarly journals Numerical Study of a Process Strategy for Improving Geometrical Accuracy in Incremental Forming Process

2019 ◽  
Vol 71 (1) ◽  
pp. 62-66 ◽  
Author(s):  
Mihai-Octavian Popp ◽  
Mihaela Oleksik ◽  
Sever-Gabriel Racz ◽  
Gabriela-Petruța Rusu
Keyword(s):  
Incremental Forming ◽  
Numerical Study ◽  
Single Point ◽  
Good Method ◽  
Key Factors ◽  
Forming Process ◽  
Geometrical Accuracy ◽  
Backing Plate ◽  
Holding Back ◽  
Process Strategy

Abstract Incremental forming process is a relatively new process among researchers, which is yet to be implemented in automotive and aerospace industries. The researchers are studying various process strategies and methods to improve the geometrical accuracy of the parts obtained by incremental forming, because the geometry of the parts is one of the key factors holding back the process industrialization. One good method to investigate the benefits of a process strategy is by means of numerical analysis, from which the results obtained can confirm or disprove the gains of the researched strategy. The aim of this paper is to present the advantages of using a fluid under pressure as a supporting die instead of using a conventional fixed backing plate for the single point incremental forming process.

scholarly journals Parametric effects on formability of AA2024-O aluminum alloy sheets in single point incremental forming

2019 ◽  
Vol 8 (1) ◽  
pp. 1461-1469 ◽  
Author(s):  
Ajay Kumar ◽  
Vishal Gulati ◽  
Parveen Kumar ◽  
Vinay Singh ◽  
Brijesh Kumar ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Parametric Effects

scholarly journals Metasurface-generated complex 3-dimensional optical fields for interference lithography

2019 ◽  
Vol 116 (43) ◽  
pp. 21379-21384 ◽  
Author(s):  
Seyedeh Mahsa Kamali ◽  
Ehsan Arbabi ◽  
Hyounghan Kwon ◽  
Andrei Faraon
Keyword(s):  
Large Scale ◽  
Periodic Structures ◽  
Interference Lithography ◽  
Complex Structures ◽  
Proof Of Concept ◽  
Optical Fields ◽  
3 Dimensional ◽  
Diffractive Element ◽  
Wide Range ◽  
Manufacturing Techniques

Fast, large-scale, and robust 3-dimensional (3D) fabrication techniques for patterning a variety of structures with submicrometer resolution are important in many areas of science and technology such as photonics, electronics, and mechanics with a wide range of applications from tissue engineering to nanoarchitected materials. From several promising 3D manufacturing techniques for realizing different classes of structures suitable for various applications, interference lithography with diffractive masks stands out for its potential to fabricate complex structures at fast speeds. However, the interference lithography masks demonstrated generally suffer from limitations in terms of the patterns that can be generated. To overcome some of these limitations, here we propose the metasurface-mask–assisted 3D nanofabrication which provides great freedom in patterning various periodic structures. To showcase the versatility of this platform, we design metasurface masks that generate exotic periodic lattices like gyroid, rotated cubic, and diamond structures. As a proof of concept, we experimentally demonstrate a diffractive element that can generate the diamond lattice.

Single Point Incremental Forming of Large Sheet Metal Components

2019 ◽  
Author(s):  
Frank Schieck ◽  
Reinhard Mauermann ◽  
Dieter Weise ◽  
Matthias Demmler
Keyword(s):  
Sheet Metal ◽  
Large Scale ◽  
Incremental Forming ◽  
Single Point ◽  
Research Work ◽  
Basic Research ◽  
Good Alternative ◽  
Batch Size ◽  
Simulation And Optimization ◽  
Wide Range

Abstract The production of complex, large-scale cladding parts made of metal in small quantities for a wide range of applications in architecture, power generation, shipbuilding, but also rail vehicle construction, mobile work machines and, last but not least, automotive sector is a major challenge in terms of principled manufacturability, but also in terms of manufacturing costs. Appropriate components are often produced in small quantities by hand, whereby the reproducibility and achievable quality depend largely on the experience and craftsmanship of the employer. The incremental forming using CNC-controlled machine tools or robots offers a good alternative for an efficient and reproducible production of sheet metal components with batch size one. There are already a large number of research work, studies and examples of applications worldwide regarding principled incremental forming strategies, process layout, FE simulation and optimization strategies. The Fraunhofer IWU works with the claim of applied research, that is, to transfer results from basic research into an industrial application. This also applies to the field of incremental sheet metal forming. Especially in the area of large-scale, 3-dimensional components, there is a very great need on the part of the industry. The paper provides an overview of current research results in the field of incremental forming of industrially relevant large-scale structures up to dimensions of approximately 4 × 2 meters, which are carried out in the single point process on a modified large milling machine. The topic of shape storage (molds), flexible clamping frames and heating equipment for temperature-supporting incremental forming of light metals is also addressed. The outlook identifies application and development potential aimed at both the further development of the technology and the associated equipment technology.

scholarly journals Numerical Study about the Influence of Wall Angle about Main Strains, Thickness Reduction and Forces on Single Point Incremental Forming Process

2016 ◽  
Vol 68 (1) ◽  
pp. 1-6 ◽  
Author(s):  
Valentin Oleksik
Keyword(s):  
Incremental Forming ◽  
Numerical Study ◽  
Single Point ◽  
Testing Machine ◽  
Thickness Reduction ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Angle ◽  
Traction Test ◽  
Explicit Dynamic

Abstract The current paper aims to study, using numerical simulation, the influence of the wall angle on the single point incremental forming process. For the analysis there has been used the LS-Dyna software and three explicit dynamic analyses were run for three parts with wall angles of 450, 550 and 650. The factors taken into account are the main strains, the thickness reduction and the forces on three directions. The material data introduced into the simulation were determined based on an uniaxial traction test on an Instron 5587 testing machine and the Aramis system was used as optical extensometer.

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