Geometric accuracy of incremental sheet forming for TRIP590

2017 ◽  
Vol 31 (11) ◽  
pp. 5257-5264 ◽  
Author(s):  
Lihua Li ◽  
Jin Wang ◽  
Baoping Wang
Keyword(s):  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy

A Mixed Toolpath Strategy for Improved Geometric Accuracy and Higher Throughput in Double-Sided Incremental Forming

2014 ◽  
Author(s):  
Rui Xu ◽  
Huaqing Ren ◽  
Zixuan Zhang ◽  
Rajiv Malhotra ◽  
Jian Cao
Keyword(s):  
Incremental Forming ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Recent Past ◽  
Forming Process ◽  
Process Flexibility ◽  
Formed Part ◽  
Future Work

Incremental sheet forming has attracted considerable attention in the recent past due to advantages that include high process flexibility and higher formability as compared to conventional forming processes. However, attaining required geometric accuracy of the formed part is one of the major issues plaguing this process. The Double-Sided Incremental Forming process has emerged as a potential process variant which can preserve the process flexibility while maintaining required geometric accuracy. This paper investigates a mixed toolpath for Double-Sided Incremental Forming which is able to simultaneously achieve good geometric accuracy and higher throughput than is currently possible. The geometries of parts formed using the mixed toolpath strategy are compared to the desired geometry. Furthermore, an examination of the forming forces is used to uncover the reasons for experimentally observed trends. Future work in this area is also discussed.

scholarly journals Cranial Reconstruction Using Double Side Incremental Forming

2015 ◽  
Vol 639 ◽  
pp. 535-542 ◽  
Author(s):  
Bin Lu ◽  
Dong Kai Xu ◽  
Run Zhe Liu ◽  
Heng An Ou ◽  
Hui Long ◽  
...  
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Pure Titanium ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Backing Plate ◽  
Cranial Implant

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Comparing to conventional sheet forming processes, ISF is of a clear advantage in manufacturing small batch or customized products such as cranial implant. Although effort on cranial reconstruction by using incremental sheet forming approach has been made in recent years, research has been mostly based on the single point incremental forming (SPIF) strategy and there are still considerable technical challenges for achieving better geometric accuracy, thickness distribution and complex cranial shape. In addition, the use of a backing plate or supporting die reduces the process flexibility and increases the cost. To overcome these limitations, double side incremental sheet forming (DSIF) process is employed for forming Grade 1 pure titanium sheet by using different toolpath strategies. The geometric accuracy and thickness distribution of the final part are evaluated so the optimized tool path strategies are developed. This leads to an assessment of the DSIF based approach for the application in cranial reconstruction.

scholarly journals A Novel Tool to Enhance The Lubricant Efficiency On Induction Heat-Assisted Incremental Sheet Forming of Ti-6Al-4V Sheets

2022 ◽  
Author(s):  
Weining Li ◽  
Khamis Essa ◽  
Sheng Li
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Water Channel ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Water Cooling ◽  
Geometric Accuracy ◽  
Molybdenum Disulphide ◽  
Roughness Analysis ◽  
Pass Through

Abstract For heat-assisted single point incremental sheet forming (SPIF) works of Ti-6Al-4V sheets, the use of lubricant has shown significant effects on surface quality and geometric accuracy at higher temperatures. Molybdenum disulphide (MoS2) is a common lubricant widely used in SPIF works, however, it usually indicates ineffective performance at high temperatures. This article has studied different lubricants of MoS2 lubricants and proposed a novel mixture of MoS2 to provide better surface quality and improve geometric accuracy. A forming tool with a ball-roller and water channel was designed to enable the MoS2 mixture to pass through the tool tip, allowing easy application of the lubricant on the localised area and reduce the thermal expansion on the ball-roller. Surface roughness analysis has revealed that the water-cooling MoS2 mixture performed well in reducing friction effects and achieved better geometric accuracy. Forming forces measurements, scanning electron microscope (SEM), energy dispersive X-ray Analysis (EDX) and micro-hardness tests also indicated that a higher strain hardening behaviour was detected for the water-cooling MoS2 mixture.

scholarly journals Incremental sheet forming of thermoplastics: a review

2020 ◽  
Vol 111 (1-2) ◽  
pp. 565-587
Author(s):  
Hui Zhu ◽  
Hengan Ou ◽  
Atanas Popov
Keyword(s):  
Process Parameters ◽  
Flexible Manufacturing ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Metallic Materials ◽  
Processing Conditions ◽  
Geometric Accuracy ◽  
Significant Progress ◽  
Research Directions ◽  
Made In

Abstract Incremental sheet forming (ISF) is a promising flexible manufacturing process, which has been tested in sheet forming of various metallic materials. Although ISF-based forming of thermoplastics is relatively new, it has drawn considerable interests and significant progress has been made in recent years. This paper presents a review of concurrent research on the emerging trend of thermoplastic-focused ISF processes. Attention is given to the processing conditions including process setup, process parameters and forming forces. The deformation mechanism and failure behaviour during ISF of thermoplastics are evaluated, which leads to detailed discussions on the formability, effect of different process parameters and the forming quality such as geometric accuracy, surface finish and other consideration factors in ISF of thermoplastics. A comparison of important similarities and differences between ISF of thermoplastic and metallic materials is made. Finally, a brief discussion is provided on the technical challenges and research directions for ISF of thermoplastic materials in the future.

Customized cranial implant manufactured by incremental sheet forming using a biocompatible polymer

2018 ◽  
Vol 24 (1) ◽  
pp. 120-129 ◽  
Author(s):  
Isabel Bagudanch ◽  
María Luisa García-Romeu ◽  
Ines Ferrer ◽  
Joaquim Ciurana
Keyword(s):  
Incremental Forming ◽  
Raw Materials ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Scanning System ◽  
Geometric Accuracy ◽  
Biocompatible Polymer ◽  
Content Type ◽  
Cranial Implant

Purpose The purpose of this paper is to demonstrate the feasibility of incremental sheet forming (ISF), using the most common variants, single-point incremental forming (SPIF) and two-point incremental forming (TPIF), to produce prototypes of customized cranial implants using a biocompatible polymer (ultrahigh molecular weight polyethylene, UHMWPE), ensuring an appropriate geometric accuracy and cost. Design/methodology/approach The cranial implant is designed based on computerized tomographies (CT) of the patient, converting them into a 3D model using the software InVesalius. To generate the toolpath for the forming operation computer-aided manufacturing (CAM) software is used. Once the cranial implant is manufactured, a 3D scanning system is used to determine the geometric deviation between the real part and the initial design. Findings The results corroborate that it is possible to successfully manufacture a customized cranial implant using ISF, being able to improve the geometric accuracy using the TPIF variant with a negative die. Originality/value This paper is one of the first research works in which a customized cranial implant is successfully manufactured using a flexible technology, ISF and a biocompatible polymer. The use of polymeric implants in cranioplasty is advantageous because of their lightweight, low heat conductivity and mechanical properties similar to bone. Furthermore, the cost of the implant has been calculated considering not only the raw materials and manufacturing time but also the environmental impact, revealing that it is a cheap process with a low lead-time.

The effect of partially cut-out blanks on geometric accuracy in incremental sheet forming

2010 ◽  
Vol 210 (11) ◽  
pp. 1501-1510 ◽  
Author(s):  
Julian M. Allwood ◽  
Daniel Braun ◽  
Omer Music
Keyword(s):  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy

FlexDie: A Flexible Tooling-Concept for Incremental Sheet Forming

2012 ◽  
Vol 504-506 ◽  
pp. 883-888 ◽  
Author(s):  
Gerd Sebastiani ◽  
Arthur Wawrosch ◽  
Volker Franzen ◽  
Alexander Brosius ◽  
A. Erman Tekkaya
Keyword(s):  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Support Tool ◽  
Part Geometry ◽  
Complex Process ◽  
Critical Zones ◽  
Similar Accuracy ◽  
Flexible Die ◽  
The Given

Forming tasks in Sheet Metal Prototyping are currently a balancing act between part flexibility and accuracy. In view of Asymmetric Incremental Sheet Forming (AISF), the part support is the decisive factor: Die-based processes such as TPIF are restricted to the given geometry of the part. On the other hand, the die-less variant (SPIF) is prone to a much more complex process-layout – once a similar accuracy needs to be obtained. Consequently, this requires a flexible die concept, supporting the part in the critical zones only. Within this article we meet this challenge by introducing the configurable tooling concept "FlexDie". This support tool comprises a construction kit for skeleton dies allowing for an adjustment of its geometry to almost any desired shape. Based on the solar cooker benchmark by Jeswiet et al., we show both the tooling-concept and the feasibility. The latter we discuss, based on the quality features geometric accuracy as well as surface quality. Both features are assessed with respect to the forming results obtained by use of a full-die. The accuracy resulting by applying the FlexDie is only slightly inferior to the parts formed by use of a full-die. However, the FlexDie allows for simple optimization of both, die and part geometry. In addition, compensation strategies by adapting the toolpath are still possible. In summary, the results show the feasibility of the FlexDie concept for industrial ISF tasks - even at very low production volumes.

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