scholarly journals The Performance of 3D Printed Polymer Tools in Sheet Metal Forming

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1256
Author(s):  
Fabio Tondini ◽  
Alberto Basso ◽  
Ulfar Arinbjarnar ◽  
Chris Valentin Nielsen
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Spring Back ◽  
Bend Radius ◽  
Nose Radius ◽  
Aluminum Sheets ◽  
3D Printed ◽  
Small Production ◽  
Back Angle ◽  
Bulk Part

Additively manufactured polymer tools are evaluated for use in metal forming as prototype tools and in the attempt to make sheet metal more attractive to small production volumes. Printing materials, strategies and accuracies are presented before the tools and tested in V-bending and groove pressing of 1 mm aluminum sheets. The V-bending shows that the tools change surface topography during forming until a steady state is reached at around five strokes. The geometrical accuracy obtained in V-bending is evaluated by the spring-back angle and the resulting bend radius, while bending to 90° with three different punch nose radii. The spring-back shows additional effects from the elastic deflection of the tools, and the influence from the punch nose radius is found to be influenced by the printing strategy due to the ratio between tool radius and the printed solid shell thickness enclosing the otherwise less dense bulk part of the tool. Groove pressing shows the combined effect of groove heights and angular changes due to spring-back. In all cases, the repeatability is discussed to show the potential of tool corrections for obtaining formed parts closer to nominal values.

APPLICATION OF 3D PRINTING TECHNOLOGY FOR RAPID TOOLING IN SHEET METAL FORMING

2020 ◽  
Vol 3 ◽  
pp. 20-30
Author(s):  
M.A. SEREZHKIN ◽  
D.O. KLIMYUK ◽  
A.I. PLOKHIKH
Keyword(s):  
3D Printing ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Rapid Tooling ◽  
Printing Technology ◽  
3D Printing Technology ◽  
3D Printed ◽  
Printed Materials ◽  
Printing Parameters

The article presents the study of the application of 3D printing technology for rapid tooling in sheet metal forming for custom or small–lot manufacturing. The main issue of the usage of 3D printing technology for die tooling was discovered. It is proposed to use the method of mathematical modelling to investigate how the printing parameters affect the compressive strength of FDM 3D–printed parts. Using expert research methods, the printing parameters most strongly affecting the strength of products were identified for further experiments. A method for testing the strength of 3D–printed materials has been developed and tested.

Experimental Study on Electromagnetic Forming of Copper Sheets

2013 ◽  
Author(s):  
Shanmuga Sundaram Karibeeran ◽  
Rajiv Selvam
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Weight Ratio ◽  
Cost Effective ◽  
Electromagnetic Forming ◽  
Light Weight ◽  
Thin Sheets ◽  
Spring Back ◽  
Aerospace Applications ◽  
Copper Aluminum

The sheet metal forming of copper, aluminum alloys using conventional stamping processes posses various problems, because of the lower formability limits, spring back and the tendency to wrinkle compared to steel. The principle of electromagnetism using attractive force is adopted to modify the conventional stamping process, to form thin sheets of 0.05 mm thickness. Further, this process can be used to form many sheet metal components with less expensive tooling and lesser number of operations. This process ultimately leads to light weight, cost effective and better strength-to-weight ratio components required for aerospace applications. In this study, a maximum of 30.77 % reduction in diameter was observed at 2.75A using electromagnetic forming which leads to the absence of spring back.

The Effect of Anisotropy on Spring-Back of CK67 Steel Sheet in L-Dies Bending Processes

2011 ◽  
Vol 291-294 ◽  
pp. 672-675
Author(s):  
Jafar Bazrafshan ◽  
A. Gorji ◽  
A. Taghizadeh Armaky
Keyword(s):  
Numerical Simulations ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Steel Sheet ◽  
Elastic Recovery ◽  
Sheet Thickness ◽  
Bend Angle ◽  
Spring Back ◽  
Geometric Changes

One of the most sensitive features of sheet metal forming processes is the elastic recovery during unloading, called spring-back, which leads to some geometric changes in the product. This phenomenon will affect bend angle and bend curvature, and can be influenced by various factors. In this research, the effects of sheet thickness and die radiuses an sheet anisotropy on spring-back in L-die bending of CK67 steel sheet were studied by experiments and numerical simulations.

Study on Spring-Back of CU11000 Clad AL1050 Sheets

2014 ◽  
Vol 941-944 ◽  
pp. 1688-1691
Author(s):  
Shou Fa Liu ◽  
Fei Xue ◽  
Song Lin Wu
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Spring Back ◽  
Bend Radius ◽  
Cu Content ◽  
Element Simulation ◽  
Bending Process ◽  
Clad Metals ◽  
Simulation And Experiment ◽  
Back Angle

This study is aimed to investigate the spring-back angle of clad metal sheet in bending process by using finite element simulation and experiment to meet the growing requires in the application of clad metals. In this study, the clad metals processed into 1mm thick from CU11000 and AL1050 were bent 90o over a die with a bend radius of 1mm. The results show that there is not any relative sliding, crushing or peeling occurred in the junction of the clad material during the bending process, the spring-back angle of the clad metal is always smaller than each single metal and the CU content increasing also caused spring-back angle become small. The configuration of a harder material (CU11000) in tensile side also has a smaller spring-back angle.

An Analytical Model to Reduce Spring-Back in Incremental Sheet Metal Forming (ISMF) Process

2009 ◽  
Vol 83-86 ◽  
pp. 1113-1120 ◽  
Author(s):  
Mehdi Vahdati ◽  
Mohammad Sedighi ◽  
Hossein Khoshkish
Keyword(s):  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Sheet Thickness ◽  
Spring Back ◽  
Step Size ◽  
Influence Of Process Parameters ◽  
Incremental Sheet Metal Forming ◽  
Tool Diameter

In this paper, spring-back and its effect on geometrical and dimensional accuracy of incremental sheet metal forming (ISMF) process has been studied. The influence of process parameters such as: vertical step size, sheet thickness, tool diameter, feed rate and spindle speed have been investigated. A series of experimental tests have been carried out for a straight groove bead-shape part made of aluminum sheets. A reliable statistical analysis has been carried out to extract the importance of each parameter. The obtained model permits to select appropriate process parameters to reduce spring-back effectively.

A Method of Die Surface Compensation after Spring Back Prediction in Sheet Metal Forming

2013 ◽  
Vol 313-314 ◽  
pp. 157-163
Author(s):  
Xiao Da Li ◽  
Xiang Hui Zhan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Interpolation Method ◽  
Mapping Method ◽  
Spring Back ◽  
Surface Interpolation ◽  
Spline Surface ◽  
Die Surface ◽  
Coordinate Mapping

Spring back in the process of sheet metal forming leads to deviations between design sizes and actual dimensions of stamping parts, to meet the precision requirements of deviations, the shape of die surface needs to be compensated in the opposite direction according to the predicted spring back by numerical simulation. In this article, the R S coordinate mapping method is used to revise coordinates of finite element nodes according to the predicted spring back, and the bi-cubic B spline surface interpolation method is applied to reconstruct die surface with CAD data format. An example shows that the algorithms are feasible and have some practical values.

scholarly journals Springback Analysis in Sheet Metal Forming Using Modified Ludwik Stress-Strain Relation

2013 ◽  
Vol 2013 ◽  
pp. 1-11 ◽  
Author(s):  
Sanjay Kumar Patel ◽  
Radha Krishna Lal ◽  
J. P. Dwivedi ◽  
V. P. Singh
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Spring Back ◽  
Stress Strain ◽  
Strain Relation ◽  
Stress Strain Relation ◽  
Strain Relationship ◽  
Von Mises ◽  
Strain Hardening Index

This paper deals with the springback analysis in sheet metal forming using modified Ludwik stress-strain relation. Using the deformation theory of plasticity, formulation of the problem and spring back ratio is derived using modified Ludwik stress strain relationship with Tresca and von Mises yielding criteraia. The results have been representing the effect of different value of or ratio, different values of Strain hardening index (), Poisson’s ratio (), and thickness on spring back ratio (). The main aim of this paper is to study the effects of the thickness, ratio, and Poisson’s ratio in spring back ratio.

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