Importance of Feature Sequencing in Incremental Forming

2015 ◽  
Author(s):  
Rakesh Lingam ◽  
C. L. Harikrishnan ◽  
I. V. M. Kishan ◽  
N. Venkata Reddy
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Multiple Features ◽  
Fixed Boundary ◽  
Local Support ◽  
Volume Production ◽  
Low Volume ◽  
Flexible Forming Process

Incremental Sheet Forming (ISF) is a flexible forming process suitable for low volume production of sheet metal components. Single Point Incremental Forming (SPIF), which has only one tool forming the geometry, is the simplest variant of incremental forming. Bending of sheet between the component opening and the fixed boundary is unavoidable in SPIF due to the absence of support/backup. Double Sided Incremental Forming (DSIF) has two tools which can be used interchangeably for forming and providing local support. The accuracy of parts formed using DSIF is superior to those formed using SPIF as the unwanted bending is substantially reduced by providing local support. In addition DSIF is capable of forming components with features on both sides of the initial plane of sheet and convex and concave features without additional setup. In ISF, as the deformation progresses, the intended geometry slowly develops, this increases the stiffness of the sheet. While forming multiple features, the forming sequence greatly affects the way stiffness builds-up, which further affects the geometry of formed components. In the present work, an experimental investigation is carried out to demonstrate the affect of forming sequence on the geometries and accuracy of formed component. Results presented show that the feature sequencing greatly affects the geometry and accuracy of formed components.

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.

Comparative Study of Incremental Forming and Elevated Temperature Incremental Forming Through Experimental Investigations on AA 1050 Sheet

2020 ◽  
Vol 143 (6) ◽  
Author(s):  
Swarit Anand Singh ◽  
Satwik Priyadarshi ◽  
Puneet Tandon
Keyword(s):  
Elevated Temperature ◽  
Room Temperature ◽  
Incremental Forming ◽  
Vital Role ◽  
Experimental Investigations ◽  
Forming Process ◽  
If Technique ◽  
Volume Production ◽  
Scope Of Application ◽  
Flexible Forming Process

Abstract Unlike conventional forming processes, incremental forming (IF) does not require any part-specific tooling. It is a flexible forming process that is suitable to form user-specific shapes and for low volume production. The IF process has been recognized as a promising manufacturing process over conventional forming for the materials having decent formability. However, it does not give reliable results while forming hard to form materials. A few investigations revealed that heat plays a vital role in enhancing the formability. On heating, the yield stress of the materials gets reduced, the ductility increases, and hence the formability improves. Thus, for the materials having poor formability, an advance IF technique, elevated temperature incremental forming (ET-IF), has been developed. ET-IF involves incremental forming of the sheets while being heated by an external heat supply. This research study focuses on the execution of the ET-IF process and its comparison with the conventional IF process. A radiation type heating device to perform the ET-IF process is designed and fabricated. The experimental investigations were carried out on 1 mm thick AA 1050 sheets by carrying out the IF process at room temperature and enhanced temperatures. Experimentation was initiated with performing straight grove tests, which were later extended to form a few more shapes. Experimental results confirm the delay in fracture and intensification of formability with the ET-IF process in comparison to that of the IF process at room temperature. The work overcomes the limitation and enlarges the scope of application of the IF process.

Custom Manufacture of a Solar Cooker – A Case Study

2005 ◽  
Vol 6-8 ◽  
pp. 487-492 ◽  
Author(s):  
J. Jeswiet ◽  
Joost R. Duflou ◽  
Alexander Szekeres ◽  
P. Lefebvre
Keyword(s):  
Developing Country ◽  
Incremental Forming ◽  
Single Point ◽  
Rapid Prototype ◽  
Single Point Incremental Forming ◽  
Country Market ◽  
Volume Production ◽  
Volume Product ◽  
Low Volume

Single Point Incremental Forming is a new process, which has been developed to make both Rapid Prototyped products and low volume product batches from Sheet Metal. This paper presents a case study of the manufacture of a solar cooker cavity for developing country applications. In the first instance the request was for a rapid prototype, which quickly evolved into a request for low volume production of solar cookers for the developing country market. The paper describes the manufacture of the solar cooker cavity, and shows how the possibility of manufacturing part of the solar cooker, by Single Point Incremental Forming, gives rise to the possibility of manufacturing other parts for the solar cooker less expensively.

scholarly journals Design and manufacturing of a fixing device for incremental sheet forming process

2018 ◽  
Vol 178 ◽  
pp. 02004 ◽  
Author(s):  
Daniel Nasulea ◽  
Gheorghe Oancea
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Incremental Forming ◽  
Single Point ◽  
Fem Simulation ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Design And Manufacturing

In incremental sheet forming processes, the expensive dedicated tool are avoided and replaced with a cheap and simple fixing device which support the sheet metal blanks. The current paper presents how a fixing device used for single point incremental forming device is designed, FEM simulated and manufactured. The fixing device can be used for parts with a cone frustum and pyramidal frustum made of DC05 deep drawing steel. The forces developed in the process and the device displacements were estimated using FEM simulation. The device components were manufactured using a CNC machines and the physical assembly is also presented in the paper.

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.

Geometry Compensation Methods for Increasing the Accuracy of the SPIF Process

2021 ◽  
Vol 883 ◽  
pp. 217-224
Author(s):  
Yannick Carette ◽  
Marthe Vanhulst ◽  
Joost R. Duflou
Keyword(s):  
Control Strategy ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Calculation Methods ◽  
Forming Process ◽  
Complex Deformation ◽  
Commercial Use ◽  
Compensation Methods ◽  
Deformation Mechanics

Despite years of supporting research, commercial use of the Single Point Incremental Forming process remains very limited. The promised flexibility and lack of specific tooling is contradicted by its highly complex deformation mechanics, resulting in a process that is easy to implement but where workpiece accuracy is very difficult to control. This paper looks at geometry compensation as a viable control strategy to increase the accuracy of produced workpieces. The input geometry of the process can be compensated using knowledge about the deformations occurring during production. The deviations between the nominal CAD geometry and the actual produced geometry can be calculated in a variety of different ways, thus directly influencing the compensation. Two different alignment methods and three deviation calculation methods are explained in detail. Six combined deviation calculation methods are used to generate compensated inputs, which are experimentally produced and compared to the uncompensated part. All different methods are able to noticeably improve the accuracy, with the production alignment and closest point deviation calculation achieving the best results

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.

Experimental Investigation of Single Point Incremental Forming of Aluminum Sheet in Groove Test

2017 ◽  
Vol 867 ◽  
pp. 177-183 ◽  
Author(s):  
Vikrant Sharma ◽  
Ashish Gohil ◽  
Bharat Modi
Keyword(s):  
Experimental Investigation ◽  
Incremental Forming ◽  
Single Point ◽  
Fractional Factorial ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Backing Plate ◽  
Groove Test ◽  
Factorial Design Of Experiments ◽  
Tool Diameter

Incremental sheet forming is one of the latest processes in sheet metal forming industry which has drawn attention of various researchers. It has shown improved formability compared to stamping process. Single Point Incremental Forming (SPIF) process requires only hemispherical tool and no die is required hence, it is a die-less forming process. In this paper experimental investigation on SPIF for Aluminium sheet has been presented. A groove test on Vertical Machining Centre has been performed. Factors (Step depth, Blank holder clamping area, Backing plate radius, Program strategy, Feed rate and Tool diameter) affecting the process are identified and experiments are carried out using fractional factorial design of experiments. Effect of the factors on fractured depth, forming time and surface finish have been analyzed using Minitab 17 software.

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