Incremental Forming of Friction Stir Welded Taylored Sheets

2006 ◽  
Author(s):  
G. Ambrogio ◽  
L. Fratini ◽  
F. Micari
Keyword(s):  
Metal Forming ◽  
Cost Reduction ◽  
Large Scale ◽  
Incremental Forming ◽  
Research Work ◽  
Sheet Thickness ◽  
Friction Stir ◽  
Tailored Blanks ◽  
Metal Stamping ◽  
Light Components

In the last decade sheet metal forming market has undergone substantial mutations since the development of more efficient strategies in terms of flexibility and cost reduction is strictly due. Such requirements are not consistent with traditional metal stamping processes which are characterized by complex equipment, capital and tooling costs; thus the industrial application of such processes is economically convenient just for large scale productions. For this reason most of the research work developed in the last years has been focused on the development of new sheet forming processes able to achieve the above discussed goals. Contemporary, with particular reference to the automotive industries the requirement of light components and the engineering of the outer skin parts of the vehicles have determined the growing utilization of tailored blanks characterized by either different material or different sheet thickness. In the paper SPIF processes of FS welded aluminium blanks are investigated in order to analyse the product properties in terms of strength and formability. A proper experimental investigation has been carried out and interesting guidelines have been highlighted in the next paragraphs.

Constant Heat Input Friction Stir Welding of Variable Thickness AZ31 Sheets Through In-Process Tool Rotation Control

2019 ◽  
Vol 141 (8) ◽  
Author(s):  
Gianluca Buffa ◽  
Davide Campanella ◽  
Archimede Forcellese ◽  
Livan Fratini ◽  
Michela Simoncini ◽  
...  
Keyword(s):  
Variable Thickness ◽  
Heat Input ◽  
Weld Line ◽  
Sheet Thickness ◽  
Strain Curve ◽  
Thickness Change ◽  
Friction Stir ◽  
Tailored Blanks ◽  
Joint Properties ◽  
Tool Rotation

Tailored blanks characterized by variable thickness were friction stir welded (FSWed) with the aim to obtain constant joint properties along the weld seam, regardless of the thickness change. To pursue this goal, the heat input was kept constant by in-process control of tool rotation. A dedicated numerical model of the process was used to determine the tool rotation values as a function of the sheet thickness. The mechanical properties and the microstructure of the FSWed joints, produced with varying process parameters, were studied. It was found that the proposed approach can produce joints with uniform properties along the weld line in terms of stress–strain curve shape, joint strength, elongation at failure, and microstructure.

Review of the effect of process parameters on performance measures in the incremental sheet forming process

2020 ◽  
pp. 095440542096121
Author(s):  
Ashish Gohil ◽  
Bharat Modi
Keyword(s):  
Process Parameters ◽  
Metal Forming ◽  
Lead Time ◽  
Incremental Forming ◽  
Low Cost ◽  
Research Work ◽  
Sheet Forming ◽  
Commercial Production ◽  
Incremental Sheet Forming ◽  
Forming Process

Incremental sheet forming process has developed the interest of researchers in the field of sheet metal forming due to high formability and capability to produce prototypes of new products at low cost and minimum lead time. Research work is going on in various front to enhance the process capabilities so that it can be explored for commercial production. In this article, progress and recent development in the field of incremental forming has been reviewed and presented for the benefit of practicing engineers and industry. The effect of various process parameters on the performance of the process have been summarized in this paper. Moreover, the issues which need attention are discussed towards the conclusion of this paper.

scholarly journals Investigation of Effects of Material Dimensions on Wrinkling in Flexforming Process

2021 ◽  
Author(s):  
Gürhan Yılgın ◽  
Oguzhan Yilmaz ◽  
Fahrettin Ozturk ◽  
Hasan Ali Hatipoglu
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Flexible Manufacturing ◽  
Research Work ◽  
Sheet Thickness ◽  
Production Costs ◽  
Material Condition ◽  
Material Conditions ◽  
Experimental Findings

Abstract Sheet metal forming processes are very common manufacturing and leading processes in automotive and aerospace industries. Flexforming is one of the sheet metal forming processes which is preferable due to its flexible manufacturing capabilities and its ability to produce multiple parts simultaneously. Convex contoured shaped parts are very much used in aerospace structures which are mostly produced by flexforming. Wrinkling is a characteristic defect for those kinds of parts. Prediction of wrinkling before manufacturing is highly crucial in order to reduce scrap rates, labor time, and other unexpected costs. In this research work, extensive amounts of experiments are conducted on flexforming press, and the process parameters such as material condition, contour radius, flange length, and material thickness which induce wrinkling are investigated in detail. Results have shown that sheet thickness is the most effective parameter, and as the sheet thickness is increased, wrinkling tendency is reduced extensively. Besides, increasing convex contour radius decreases wrinkling occurrence. Experimental findings are then used to generate wrinkling limit diagrams in which safety and failure zones are specified for different material conditions and sheet thicknesses. The developed diagrams might help to designer who can design defect free parts, reduce scrap rates, and reduce production costs significantly.

scholarly journals Investigation on tailored blanks in a full forward extrusion process of sheet-bulk metal forming

2021 ◽  
Author(s):  
Manuel Reck ◽  
Marion Merklein
Keyword(s):  
Heat Treatment ◽  
Metal Forming ◽  
Material Flow ◽  
Sheet Thickness ◽  
Extrusion Process ◽  
Functional Elements ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Forward Extrusion ◽  
Tailored Blanks

Due to the ongoing technological development, the demand for geometrically complicated high performance parts with great functional density is increasing. Often, the use of sheet metal is a beneficial approach in manufacturing technology to meet the requirements on components regarding material strength and lightweight construction goals. The forming of therefore required complex sheet metal part geometries with integrated functional elements cause the need for a three dimensional material flow. Sheet-bulk metal forming, characterized by the application of bulk forming operations on sheet metals, is a suitable approach to produce such components. A challenge is the material flow control, resulting in an insufficient die filling of the functional elements. The use of tailored blanks with a defined sheet thickness distribution is an auspicious approach to face this challenge in subsequent forming processes. In the presented work, semi-finished products with a continuous thickness profile manufactured by orbital forming are applied in a full forward extrusion process. By an additional implementation of a heat treatment, the tailored blanks undergo a recrystallization process that causes a softening of the strain hardened material. In this paper, the potential of a heat treatment in the process class of sheet-bulk metal forming is shown by characterizing the geometrical and mechanical properties of the functional components by applying the mild deep drawing steel DC04 with an initial sheet thickness of t0 = 2.0 mm.

Comparison of incremental sheet metal forming process using newly designed multipoint tool with the existing single point tool by optimization and characterization methods on austenite stainless steel 202

2021 ◽  
pp. 095440542098609
Author(s):  
Ramkumar Kathalingam ◽  
Baskar Neelakandan ◽  
Elangovan Krishnan ◽  
Sathiya Narayanan Chinnayan ◽  
Selvarajan Arangulavan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Research Work ◽  
Forming Process ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming

Incremental Sheet metal Forming (ISF) is a reliable process of converting a blank to work piece with better outputs compared to conventional forming process. The flexibility of ISF in producing the rapid prototype based on the customer needs is increased which is also desirable in the industry. But Single Point Incremental Forming (SPIF) process takes more time to form a product and hence the longer time is a barrier in implementing this process in industries. In this research work, the ISF process was made on sheet metal SS 202 using a newly designed multi-point tool and the obtained outputs were compared with the same material of sheet metal formed by traditionally available single point tool. This Multi Point Incremental Forming (MPIF) process takes lesser process time to give better formability, improved wall angle and good surface roughness. The input process parameters selected for the process are type of tool, speed, feed, Vertical Step Depth (VSD), and lubrication. They are arranged by using the taguchi Design of Experiments (DOE) approach. The responses considered are wall angle, formability, surface roughness, spring back and forming time. The multiple outputs obtained were optimized by Grey Relational Analysis (GRA) to predict the superior parameter. Confirmation test was also made to validate the output result. Fractography analysis was carried out to predict the fracture mechanism obtained during the forming process. The surface topography was also made on the surface of the formed area of the sheet metal. This research work concludes that newly designed MPIF outperforms SPIF.

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 On the Elastoplastic Behavior of Friction Stir Welded Tailored Blanks for Single Point Incremental Forming

2021 ◽  
Author(s):  
Fausto Tucci ◽  
António Andrade-Campos ◽  
Sandrine Thuillier ◽  
Pierpaolo Carlone
Keyword(s):  
Mechanical Properties ◽  
Model Updating ◽  
Incremental Forming ◽  
Single Point ◽  
Welding Process ◽  
Local Variation ◽  
Single Point Incremental Forming ◽  
Sheet Metals ◽  
Friction Stir ◽  
Tailored Blanks

The current market requirements are increasingly pushing the industry towards the manufacturing of highly customized products. Tailored blanks are a class of sheet metals characterized by the local variation of properties, attributable to the presence of different materials, different thickness distribution, and thermal treatments. In the manufacturing of tailored welded blanks, welding and forming processes cover a central role. In this framework, friction stir welding demonstrated to be a suitable candidate technology for the production by joining of tailored blanks. Indeed, sheet metals welded by this solid-state welding process typically exhibit high formability when compared to the conventional welding methods. Due to the improved formability, a good deal of attention has been recently given toward the single point incremental forming (SPIF) process and its integration with FSW. Remarkable efforts have been dedicated to the numerical modeling of the SPIF of metallic alloy sheets jointed by FSW. The main criticisms in these models are related to the definition of the mechanical properties of the materials, which are affected by the structural alteration induced by the FSW. The present work aims to model the local alterations in the mechanical properties and to analyze how these local characteristics affect the formability of the blanks. With this purpose, a 20 mm wide sample collected from a FS welded blank of aluminum alloy AA6082 has been modeled using the mechanical properties variation achieved in a previous work. The influence of this local variation in properties has been assessed using a Finite Element Model Updating strategy.

Formability Analyses on Single Point Incremental Sheet Forming Process on Aluminum 1050

2019 ◽  
Vol 969 ◽  
pp. 703-708
Author(s):  
Dawit Desalegn ◽  
P. Janaki Ramulu ◽  
Dagmawi Hailu ◽  
S. Senthil Kumaran ◽  
P. Velmurugan ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Forming Process ◽  
Aluminum 1050 ◽  
Tool Diameter ◽  
Truncated Pyramid

In recent years, there is a lot of demand on metal forming processes in which sheet metal forming process has lots of applications in the automotive and aerospace industries. In sheet metal forming operations, incremental forming is an emerging technology in which, single point incremental forming (SPIF) process is die-less in incremental forming process and providing a competitive alternative to economical and effective in fabricating low volume products. The objective of this work is to analyze the forming analysis on truncated pyramid product by avoiding cracking and maintaining the optimum forming conditions. The formability is analyzed by using ABAQUS software and simulation, different process parameters were varied such as sheet thickness, tool diameter, step depth, spindle rotational speed on aluminum AA1050 alloy. From the simulation results, stress stain and stain distribution were evaluated on the deformed sheet. The product produced is truncated pyramid dimension having square base of side and fillet at corner.

Excellent Formability of Light Metals Sheets by Friction Stir Incremental Forming

2016 ◽  
Vol 716 ◽  
pp. 3-10 ◽  
Author(s):  
Masaaki Otsu
Keyword(s):  
Aluminum Alloys ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Light Metals ◽  
Friction Stir ◽  
Rotation Direction ◽  
Incremental Sheet Metal Forming ◽  
Tool Rotation

The results about friction stir incremental forming of light metals sheets from the beginning of development to the latest in the author’s laboratory are introduced. Comparison of formability by the conventional single point incremental sheet metal forming and friction stir incremental forming for magnesium alloys, aluminum alloys and titanium sheets were introduced. Effect of tool rotation direction, multistage forming and double side forming are also introduced.

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