Utilization of Wavy Toolpath in Single-Point Incremental Forming

2018 ◽  
Author(s):  
Tyler J. Grimm ◽  
Ihab Ragai ◽  
John T. Roth
Keyword(s):  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Final Part ◽  
Single Point Incremental Forming ◽  
Step Down ◽  
Material Forming ◽  
Surface Variability

Incremental forming (IF) is a sheet material forming method which utilizes a hemispherically tipped tool to form material. The tool is typically CNC controlled along a path which outlines the contours of the final geometry. The most common toolpaths used during forming are the spiral and step-down paths. Few variations of these toolpaths currently exist. A novel toolpathing strategy is proposed herein. This toolpath forms a wave-like path in order to mimic the effects of vibration-assisted tooling; however, with much greater control. A variation of this strategy in which the tool does not lose contact with the surface of the part throughout its path was tested. This method has been found to be an effective approach for improving the surface variability of the final part.

Study on Process Parameters on Single Point Incremental Forming of PVC

2016 ◽  
Vol 878 ◽  
pp. 74-80 ◽  
Author(s):  
Xiao Bo Zhang ◽  
Jin Wang ◽  
Shu Qin Zhang
Keyword(s):  
Incremental Forming ◽  
Influencing Factor ◽  
Sheet Material ◽  
Single Point ◽  
Sheet Thickness ◽  
Feed Speed ◽  
Single Point Incremental Forming ◽  
Angle Variable ◽  
Material Forming ◽  
Material Wear

Effects of polyvinylchloride (PVC) sheet thickness (t), feed speed (υ), spindle speed (ω), Z-axis feed rate (p) and tool head diameter (Φ) as well as their interactions during the single point incremental forming (SPIF) on forming performance of the PVC sheet material were studied through an orthogonal experimental test. In this experiment, the angle-variable cone was used and the maximum forming limiting angle was taken as the experimental index. Results showed that and ω×Φ influence forming performance of PVC sheet material significantly. υ is the main influencing factor of SPIF performance of PVC sheet material. Small υ is good for sheet material forming. p and Φ are proportional to forming performance of sheet material. Over ω will cause material wear-out. Effect of t could be neglected.

A Study on Using Cover Blank in Single Point Incremental Forming Process by Finite Element Analysis

2015 ◽  
Vol 809-810 ◽  
pp. 277-282
Author(s):  
Khalil Ibrahim Abass
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Complex Nature ◽  
Work Piece ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Highly Nonlinear

The Single Point Incremental Forming Process (SPIF) is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped. The finished part is manufactured by the CNC machine. SPIF involves extensive plastic deformation and the description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. However, due to the complex nature of these models, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study on effect of using cover blank in SPIF through FEA. The considered SPIF has been studied under certain process conditions referring to the test work piece, tool, etc., applying ANSYS 11.0. The results show that the simulation model can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool-work piece, the product accuracy by evaluation its thickness and strain distributions, the contact status and chattering among surface interface tool-work piece.

A Study of Forming Tool Profile Effect in Single Point Incremental Forming by Finite Element Analysis

2015 ◽  
Vol 760 ◽  
pp. 427-432
Author(s):  
Khalil Ibrahim Abass ◽  
Florian Draganescu
Keyword(s):  
Boundary Conditions ◽  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Material Behavior ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Tool Profile ◽  
Highly Nonlinear

The Single Point Incremental Forming Process, SPIF, is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped on fixture by holder. The finished part is performed by the CNC milling machine. The description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. Due to the fact that the mathematical analysis of SPIF is complex, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study concerning the effect of forming tool profile on SPIF through FEA, that permits the modeling of complex geometries, material behavior and boundary conditions. SPIF has been studied under certain process conditions referring to the test workpiece, tool, etc., using ANSYS 11.0. The results showed that the model of simulation can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool - workpiece, the accuracy of product by evaluation the strain and the stress distributions between forming tool and workpiece surface interface, and sample of results have been demonstrated.

Implementing Thermomechanical Properties of 22MnB5 Steel during Hot Single-Point Incremental Forming

2017 ◽  
Vol 890 ◽  
pp. 362-366 ◽  
Author(s):  
Amar Al-Obaidi ◽  
Verena Kräusel ◽  
Dirk Landgrebe
Keyword(s):  
Mechanical Properties ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Thermomechanical Properties ◽  
Alloy Sheet ◽  
Process Time ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process

The strategy in manufacturing hardened parts used in car bodies is to tailor the mechanical properties. This is done by combining together a high-strength region and a high-toughness region to ensure the crash performance required. Other successive secondary operations such as trimming, joining and welding can be improved as a result of the tailoring process. In this work, the mechanical properties of 22MnB5 alloy sheet material produced by single-point incremental forming have been tailored. For this purpose, the sheets were locally heated by induction during the forming process and subsequently cooled. The sheet temperature was controlled by the CNC milling machine feed rate and induction power. As a result, the produced tailored parts consist of three different regions: ductile, transition and hardened regions. The Vickers hardness values were 583 HV1 and 175 HV1 for the hardened and ductile regions, respectively. The proposed application allows forming and quenching at the same time without transfer and to reduce the process time.

scholarly journals A research on a new structure of forming tool in Single Point Incremental Forming (SPIF)

2020 ◽  
Vol 3 (SI1) ◽  
pp. SI157-SI163
Author(s):  
Le Khanh Dien ◽  
Nguyen Van Thanh ◽  
Nguyen Tan Hung
Keyword(s):  
Incremental Forming ◽  
Spherical Surface ◽  
Sheet Material ◽  
Single Point ◽  
Tangential Velocity ◽  
Metal Sheet ◽  
Innovative Technology ◽  
Single Point Incremental Forming ◽  
Spherical Tool ◽  
The Revolution

Single Point Incremental Forming (SPIF) is really a new technology of forming metal sheet nowadays and in recent decades. Although it was invented in, 1967 by Lezak, an American inventor, but the applications of the innovative technology were broad from 1990 because of the advance of controlling technology. This technology is especially adapted to small batch, unique or single productions. There are many forming parameters that influence to the formability of the metal sheet workpiece such as diameter of tool, the revolution per minute of the tool tip, the vertical feed rate after each orbit, the velocity of tool in horizontal plane…. Among of them, in our own experiences, we recognize that in almost all cases, the revolution per minute of the forming tool when forming ferric material sheet such as mild steel, stainless steel, hard steels… should be as small as possible to get the biggest ability of deformation of the workpiece sheet to get rid of failure on the lateral edge of the sheet. The tangential velocity of forming point on the spherical tool tip should be selected to attain the situation of rolling but no sliding of the surface of the spherical tool on the one of the sheet material. The paper recommends a new version of a forming tool in which the tip of the tool is a very hard ball (such as the quenched ball in a ball bearing) that is freely rotate by the friction to modify the contact point on the spherical surface of the tool to avoid the abrading and keep the spherical shape and the situation of rotating but no sliding on the surface of the workpiece sheet as mentioned above. The manufacture of the innovative forming tool is performed and then empirical processes verified it. The models formed by the typical tool are better in comparison with the ones of normal forming tool.

Influence of mechanical properties of the sheet material on formability in single point incremental forming

CIRP Annals ◽  
2004 ◽  
Vol 53 (1) ◽  
pp. 207-210 ◽  
Author(s):  
L. Fratini ◽  
G. Ambrogio ◽  
R. Di Lorenzo ◽  
L. Filice ◽  
F. Micari
Keyword(s):  
Mechanical Properties ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Single Point Incremental Forming

Feasibility of Past Vertical Forming Utilizing Single Point Incremental Sheet Forming

2017 ◽  
Author(s):  
Tyler J. Grimm ◽  
Ihab Ragai ◽  
John T. Roth
Keyword(s):  
Rotational Motion ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Levels Of Detail ◽  
Material Forming

Incremental forming (IF) is a novel sheet material forming technique typically restricted to drafted geometries. By utilizing tooling which features regions that extend radial from the axis of the tool, it is proposed that this restriction can be eliminated. Additionally, by controlling the rotational motion of the tool, it is proposed that greater levels of detail can be achieved in the IF process. In the following works, the feasibility of utilizing this type of tooling in the IF process is discussed, as well as several variations of such tooling. Validation of the proposed tooling is also presented.

scholarly journals Parametric Effects of Single Point Incremental Forming on Hardness of AA1100 Aluminium Alloy Sheets

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7263
Author(s):  
Sherwan Mohammed Najm ◽  
Imre Paniti ◽  
Tomasz Trzepieciński ◽  
Sami Ali Nama ◽  
Zsolt János Viharos ◽  
...  
Keyword(s):  
Aluminium Alloy ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Alloy Sheet ◽  
Single Point Incremental Forming ◽  
Regression Equations ◽  
Effective Parameters ◽  
Forming Process ◽  
Tool Diameter

When using a unique tool with different controlled path strategies in the absence of a punch and die, the local plastic deformation of a sheet is called Single Point Incremental Forming (SPIF). The lack of available knowledge regarding SPIF parameters and their effects on components has made the industry reluctant to embrace this technology. To make SPIF a significant industrial application and to convince the industry to use this technology, it is important to study mechanical properties and effective parameters prior to and after the forming process. Moreover, in order to produce a SPIF component with sufficient quality without defects, optimal process parameters should be selected. In this context, this paper offers insight into the effects of the forming tool diameter, coolant type, tool speed, and feed rates on the hardness of AA1100 aluminium alloy sheet material. Based on the research parameters, different regression equations were generated to calculate hardness. As opposed to the experimental approach, regression equations enable researchers to estimate hardness values relatively quickly and in a practicable way. The Relative Importance (RI) of SPIF parameters for expected hardness, determined with the partitioning weight method of an Artificial Neural Network (ANN), is also presented in the study. The analysis of the test results showed that hardness noticeably increased when tool speed increased. An increase in feed rate also led to an increase in hardness. In addition, the effects of various greases and coolant oil were studied using the same feed rates; when coolant oil was used, hardness increased, and when grease was applied, hardness decreased.

Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

2020 ◽  
Vol 38 (8A) ◽  
pp. 1137-1142
Author(s):  
Baqer A. Ahmed ◽  
Saad K. Shather ◽  
Wisam K. Hamdan
Keyword(s):  
Vickers Hardness ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Coil Current ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

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