scholarly journals Modeling and optimization of surface roughness in single point incremental forming process

2015 ◽  
Vol 4 (3) ◽  
pp. 304-313 ◽  
Author(s):  
Suresh Kurra ◽  
Nasih Hifzur Rahman ◽  
Srinivasa Prakash Regalla ◽  
Amit Kumar Gupta
Keyword(s):  
Surface Roughness ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Modeling And Optimization

The Effect of Lubricants and Material Properties in Surface Roughness and Formability for Single Point Incremental Forming Process

2014 ◽  
Vol 979 ◽  
pp. 359-362
Author(s):  
Nuttaphong Sornsuwit ◽  
Sunthorn Sittisakuljaroen
Keyword(s):  
Surface Roughness ◽  
Adhesive Wear ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Sheet Surface ◽  
Air Blowing ◽  
Asymmetric Shape ◽  
High Roughness

The single point incremental forming (SPIF) is a manufacturing process which allows small batch and asymmetric shape fabrication. The research focuses on its applications by consider surface roughness and formability. The surface roughness of specimen was resulted by the influence obtained between tool and specimen, where the lubricant played a significant role during the forming process, as well as material elongation as a mechanical property governed the formability of metal sheet. Surface roughness tester, SEM, EDS and profilometer were used for the characterizations. The results showed that low roughness value (Ra) of SUS 304 and SUS 316L obtained by applying air blowing as a lubricant, while Ti Gr2 could obtain low roughness by using MoS2. The behavior of wear was an adhesive wear which transfer to an abrasive wear. SUS 304 and SUS 316L sheet of test specimens achieved higher depth in forming by air lubricant and MoS2, and Ti Gr2 sheet revealed a better formability with MoS2. Furthermore, the highest depth was correlated with high roughness value for each material.

The Influence of Temperature on Secondary Forming of Titanium Gr 2 Sheet by Use of Single Point Incremental Forming

2014 ◽  
Vol 979 ◽  
pp. 351-354
Author(s):  
Nuttaphong Sornsuwit ◽  
Sunthorn Sittisakuljaroen
Keyword(s):  
Surface Roughness ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Stress Relieving ◽  
Different Temperatures ◽  
Influence Of Temperature On ◽  
Metal Forming Process ◽  
High Flexibility

The single point incremental forming (SPIF) is a sheet metal forming process with high flexibility on manufacture of each individual workpiece. However, it usually requires more processing time than a conventional forming method and is important to process with appropriate parameters. This study is to investigate the influence of different temperatures on continuing secondary forming of Ti Gr2 sheet, employed the stress relieving and annealing temperature after primary forming. The deformed parts were examined on the following criteria; internal contact surface roughness, microhardness and sectional microstructure. Stress relieving and annealing temperatures of 580°C and 780°C were applied to the formed parts prior to their secondary forming. It is found that the surface roughness increased from Ra 2.104 μm and 2.498 μm to Ra 2.55 μm and 3.18 μm respectively after secondary forming. The formability of 25 mm radius test specimens remained at 12 mm depth with limited obvious change.

The Effected of Single Point Incremental Forming Process Parameters on the Formed Part Surface Roughness

2014 ◽  
Vol 979 ◽  
pp. 335-338
Author(s):  
Kittiphat Rattanachan ◽  
Chatchapol Chungchoo
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Process Parameters ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Tool Rotational Speed ◽  
Forming Process ◽  
Inner Surface

The single point incremental forming process (SPIF) are suited for sheet metal prototyping, because it is a low cost production process that produces sheet metal part without any used of die, and easy to adjust the part’s geometry by change toolpath. But the quality of forming parts is still in doubt. In some applications, such as mould cavity for rapid mould and the medical parts, in this case the inside surface roughness plays an importance role. In this paper, the SPIF process parameters that affected to the inner surface roughness were experimental studied. The investigated parameters are composing of tool feed rate, side overlap, depth step and tool radius. The 2k-p factorial experimental design was used to analyze the interaction between each parameter. The results showed that increasing feed rate and depth step decreased inner surface roughness. Reducing tool rotational speed and feed rate reduced inner surface roughness. So increasing depth step with decreasing side overlap reduced inner surface roughness. The large tool radius and lower side overlap improved inner surface roughness. The large tool radius and higher depth step improved inner surface roughness. And last, reducing tool rotational speed with larger tool radius, the inner surface roughness is decreased.

scholarly journals Study of Friction and Wear Effects in Aluminum Parts Manufactured via Single Point Incremental Forming Process Using Petroleum and Vegetable Oil-Based Lubricants

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3973
Author(s):  
José M. Diabb Zavala ◽  
Oscar Martínez-Romero ◽  
Alex Elías-Zúñiga ◽  
Héctor Manuel Leija Gutiérrez ◽  
Alejandro Estrada-de la Vega ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Friction And Wear ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Step Size ◽  
Vertical Step ◽  
Stribeck Curves

This paper focuses on studying how mineral oil, sunflower, soybean, and corn lubricants influence friction and wear effects during the manufacturing of aluminum parts via the single point incremental forming (SPIF) process. To identify how friction, surface roughness, and wear change during the SPIF of aluminum parts, Stribeck curves were plotted as a function of the SPIF process parameters such as vertical step size, wall angle, and tool tip semi-spherical diameter. Furthermore, lubricant effects on the surface of the formed parts are examined by energy dispersive spectroscopy (EDS) and scanning electron microscope (SEM) images, the Alicona optical 3D measurement system, and Fourier-transform infrared spectroscopy (FTIR). Results show that during the SPIF process of the metallic specimens, soybean and corn oils attained the highest friction, along forces, roughness, and wear values. Based on the surface roughness measurements, it can be observed that soybean oil produces the worst surface roughness finish in the direction perpendicular to the tool passes (Ra =1.45 μm) considering a vertical step size of 0.25 mm with a 5 mm tool tip diameter. These findings are confirmed through plotting SPIFed Stribeck curves for the soybean and corn oils that show small hydrodynamic span regime changes for an increasing sample step-size forming process. This article elucidates the effects caused by mineral and vegetable oils on the surface of aluminum parts produced as a function of Single Point Incremental Sheet Forming process parameters.

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

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.

scholarly journals Common defects of parts manufactured through single point incremental forming

2021 ◽  
Vol 343 ◽  
pp. 04007
Author(s):  
Mihai Popp ◽  
Gabriela Rusu ◽  
Sever-Gabriel Racz ◽  
Valentin Oleksik
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Serial Robot ◽  
The Many ◽  
Cold Metal

Single point incremental forming is one of the most intensely researched die-less manufacturing process. This process implies the usage of a CNC equipment or a serial robot which deforms a sheet metal with the help of a relatively simple tool that follows an imposed toolpath. As every cold metal forming process, besides the many given advantages it has also some drawbacks. One big drawback in comparison with other cold metal forming processes is the low accuracy of the deformed parts. The aim of this research is to investigate the sheet metal bending mechanism through finite element method analysis. The results shows that the shape of the retaining rings has a big influence over the final geometrical accuracy of the parts manufactured through single point incremental forming.

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