An investigation into thickness distribution in single point incremental forming using sequential limit analysis

2013 ◽  
Vol 7 (4) ◽  
pp. 469-477 ◽  
Author(s):  
M. J. Mirnia ◽  
B. Mollaei Dariani ◽  
H. Vanhove ◽  
J. R. Duflou
Keyword(s):  
Limit Analysis ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Single Point Incremental Forming

Experimental Study on Residual Formability of Single Point Incrementally Formed Part

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Conventional Process

Abstract A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

Multiobjective Optimization of Single Point Incremental Forming: Comparison between Isotropic and Combined Hardening Behavior

2014 ◽  
Vol 611-612 ◽  
pp. 1031-1038 ◽  
Author(s):  
Henia Arfa ◽  
Riadh Bahloul ◽  
Hedi Belhadjsalah
Keyword(s):  
Process Parameters ◽  
Incremental Forming ◽  
Numerical Study ◽  
Kinematic Hardening ◽  
Thickness Distribution ◽  
Single Point ◽  
Surface Model ◽  
Mechanical Resistance ◽  
Single Point Incremental Forming ◽  
Incremental Step

Single point incremental forming (SPIF) of sheet metal is a promising process to produce small batch production and prototyping. This process consists of a controlled process of displacement performed on a three-axis CNC milling machine. In former work, the most critical factors which affected single point incremental forming process were found to be formed shape, tool size, material type, material thickness and incremental step size. The present work is focused on an optimization strategy of (SPIF) process determined by a numerical study based on finite element analyses (FEA) according to a Box-Behnken Design of Experiments. Two types of hardening behaviour laws of material are used: isotropic and combined isotropic-kinematic hardening behaviour. To do so, a set of numerical simulations are carried out for an aluminum truncated cone as geometry of a benchmark model. The simulation results include some decisions about the mechanical resistance and geometrical quality of the parts such as the thickness distribution and the magnitude of springback. In this paper, the main objective is to present an overview of multiobjective design optimization of process parameters in single point incremental forming operation in order to minimize the sheet thinning rate and the springback simultaneously. In this investigation, the steps of optimization procedure include the using of Box-Behnken experimental design for sample producing, response surface model for coarse fitting and a developed Multiobjective Genetic Algorithm (MOGA) for exact solving of fitness functions. The results show that these methods are able to determine all the best possible compromise with respect several antagonistic objectives as well as generate the approximate Pareto optimal solutions. So these will make it possible to choose the appropriate process parameters according to the objectives functions to be minimized and consequently the improvement of the products formed by the process of incremental forming.

Tool Path and Sheet Thickness Distribution of Axisymmetric Cup in Single Point Incremental Forming

2019 ◽  
Vol 823 ◽  
pp. 1-7
Author(s):  
Ching Lun Li ◽  
Yung Kuan Ni ◽  
Yang Haw ◽  
Yuung Hwa Lu
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Initial Portion ◽  
Tool Paths ◽  
Forming Characteristics ◽  
Inclined Angle

This study involved planning different tool paths for an axisymmetric cup to explore the forming characteristics of the single point incremental forming (SPIF) process. In addition, this study developed a gradient theory to compute the inclined angle between the tangential and horizontal directions of the cup formed using single point incremental forming. The sheet thickness distribution of the cup was also calculated. To verify the theory, circle arc cups were formed by CNC machining using different tool paths. It was found that the cup formed using the spiral evolutional snail-line tool path produced a better surface than that formed using the equal height evolutional tool path. The sheet thicknesses of circle arc cups obtained by the experiment and using the cosine law were compared. A larger deviation was noted in the initial portion of the cup, whereas a smaller deviation was found in the other portion. This study also adopted a dual-conical cup to investigate the relationship between thickness and the initial inclined angle at the initial portion. It was found that a larger initial inclined angle led to good coincidence between the experimental and theoretical sheet thicknesses.

scholarly journals Optimization of Hole-Flanging by Single Point Incremental Forming in Two Stages

Materials ◽  
2018 ◽  
Vol 11 (10) ◽  
pp. 2029 ◽  
Author(s):  
Domingo Morales-Palma ◽  
Marcos Borrego ◽  
Andrés Martínez-Donaire ◽  
Gabriel Centeno ◽  
Carpóforo Vallellano
Keyword(s):  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Optimization Procedure ◽  
Single Point Incremental Forming ◽  
Two Stage ◽  
Element Analysis ◽  
Deformation And Failure ◽  
Explicit Finite Element ◽  
Hole Flanging

Single point incremental forming (SPIF) has been demonstrated to accomplish current trends and requirements in industry. Recent studies have applied this technology to hole-flanging by performing different forming strategies using one or multiple stages. In this work, an optimization procedure is proposed to balance fabrication time and thickness distribution along the produced flange in a two-stage variant. A detailed analytical, numerical and experimental investigation is carried out to provide, evaluate and corroborate the optimal strategy. The methodology begins by analysing the single-stage process to understand the deformation and failure mechanisms. Accordingly, a parametric two-stage SPIF strategy is proposed and evaluated by an explicit Finite Element Analysis to find the optimal parameters. The study is focused on AA7075-O sheets with different pre-cut hole diameters and considering a variety of forming tool radii. The study exposes the relevant role of the tool radius in finding the optimal hole-flanging process by the proposed two-stage SPIF.

scholarly journals The Influence of Sheet Tilting on Forming Quality in Single Point Incremental Forming

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3907
Author(s):  
Hu Zhu ◽  
Yang Wang ◽  
Yibo Liu ◽  
Dongwon Jung
Keyword(s):  
Plastic Strain ◽  
Material Flow ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Quality ◽  
Cnc Incremental Forming ◽  
Formed Part ◽  
Profile Accuracy

In the CNC incremental forming process, the sheet tilting method can be used to realize the non-fracture forming of a surface with large forming angles. However, the forming effect of the formed part will have big differences when the inclined angle of the sheet is different. Therefore, four different tilted sheets with inclined angles of 15°, 20°, 25°, and 30° were used to study the influence of sheet tilting on forming quality by using 1060 Aluminum sheet as the forming sheet in single point CNC incremental forming. First, the influence of four different inclined angles of the sheet on the overall thickness distribution, plastic strain, and material flow of the formed part was studied by using numerical simulation. Then, the influence of four different inclined angles of sheets on the profile accuracy and thickness thinning rate of the formed part was studied through single point incremental forming experiments. The research results show that sheet tilting has little effect on the profile accuracy of the formed part, but has a great influence on the material flow, plastic strain, and thickness distribution.

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