Influence of mechanical properties of the sheet material on formability in single point incremental forming

CIRP Annals ◽  
2004 ◽  
Vol 53 (1) ◽  
pp. 207-210 ◽  
Author(s):  
L. Fratini ◽  
G. Ambrogio ◽  
R. Di Lorenzo ◽  
L. Filice ◽  
F. Micari
Keyword(s):  
Mechanical Properties ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Single Point Incremental Forming

Implementing Thermomechanical Properties of 22MnB5 Steel during Hot Single-Point Incremental Forming

2017 ◽  
Vol 890 ◽  
pp. 362-366 ◽  
Author(s):  
Amar Al-Obaidi ◽  
Verena Kräusel ◽  
Dirk Landgrebe
Keyword(s):  
Mechanical Properties ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Thermomechanical Properties ◽  
Alloy Sheet ◽  
Process Time ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process

The strategy in manufacturing hardened parts used in car bodies is to tailor the mechanical properties. This is done by combining together a high-strength region and a high-toughness region to ensure the crash performance required. Other successive secondary operations such as trimming, joining and welding can be improved as a result of the tailoring process. In this work, the mechanical properties of 22MnB5 alloy sheet material produced by single-point incremental forming have been tailored. For this purpose, the sheets were locally heated by induction during the forming process and subsequently cooled. The sheet temperature was controlled by the CNC milling machine feed rate and induction power. As a result, the produced tailored parts consist of three different regions: ductile, transition and hardened regions. The Vickers hardness values were 583 HV1 and 175 HV1 for the hardened and ductile regions, respectively. The proposed application allows forming and quenching at the same time without transfer and to reduce the process time.

A Study on Using Cover Blank in Single Point Incremental Forming Process by Finite Element Analysis

2015 ◽  
Vol 809-810 ◽  
pp. 277-282
Author(s):  
Khalil Ibrahim Abass
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Complex Nature ◽  
Work Piece ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Highly Nonlinear

The Single Point Incremental Forming Process (SPIF) is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped. The finished part is manufactured by the CNC machine. SPIF involves extensive plastic deformation and the description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. However, due to the complex nature of these models, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study on effect of using cover blank in SPIF through FEA. The considered SPIF has been studied under certain process conditions referring to the test work piece, tool, etc., applying ANSYS 11.0. The results show that the simulation model can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool-work piece, the product accuracy by evaluation its thickness and strain distributions, the contact status and chattering among surface interface tool-work piece.

Study on Process Parameters on Single Point Incremental Forming of PVC

2016 ◽  
Vol 878 ◽  
pp. 74-80 ◽  
Author(s):  
Xiao Bo Zhang ◽  
Jin Wang ◽  
Shu Qin Zhang
Keyword(s):  
Incremental Forming ◽  
Influencing Factor ◽  
Sheet Material ◽  
Single Point ◽  
Sheet Thickness ◽  
Feed Speed ◽  
Single Point Incremental Forming ◽  
Angle Variable ◽  
Material Forming ◽  
Material Wear

Effects of polyvinylchloride (PVC) sheet thickness (t), feed speed (υ), spindle speed (ω), Z-axis feed rate (p) and tool head diameter (Φ) as well as their interactions during the single point incremental forming (SPIF) on forming performance of the PVC sheet material were studied through an orthogonal experimental test. In this experiment, the angle-variable cone was used and the maximum forming limiting angle was taken as the experimental index. Results showed that and ω×Φ influence forming performance of PVC sheet material significantly. υ is the main influencing factor of SPIF performance of PVC sheet material. Small υ is good for sheet material forming. p and Φ are proportional to forming performance of sheet material. Over ω will cause material wear-out. Effect of t could be neglected.

A Study of Forming Tool Profile Effect in Single Point Incremental Forming by Finite Element Analysis

2015 ◽  
Vol 760 ◽  
pp. 427-432
Author(s):  
Khalil Ibrahim Abass ◽  
Florian Draganescu
Keyword(s):  
Boundary Conditions ◽  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Material Behavior ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Tool Profile ◽  
Highly Nonlinear

The Single Point Incremental Forming Process, SPIF, is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped on fixture by holder. The finished part is performed by the CNC milling machine. The description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. Due to the fact that the mathematical analysis of SPIF is complex, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study concerning the effect of forming tool profile on SPIF through FEA, that permits the modeling of complex geometries, material behavior and boundary conditions. SPIF has been studied under certain process conditions referring to the test workpiece, tool, etc., using ANSYS 11.0. The results showed that the model of simulation can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool - workpiece, the accuracy of product by evaluation the strain and the stress distributions between forming tool and workpiece surface interface, and sample of results have been demonstrated.

Mechanical Properties and Chain Orientation in Single Point Incremental Forming of Semi-Crystalline Polyamide

2016 ◽  
Author(s):  
Mohammad Ali Davarpanah ◽  
Shalu Bansal ◽  
Rajiv Malhotra
Keyword(s):  
Mechanical Properties ◽  
Incremental Forming ◽  
Single Point ◽  
Polymer Surfaces ◽  
Single Point Incremental Forming ◽  
X Ray Diffraction ◽  
Scanning Calorimetry ◽  
Chain Orientation ◽  
The Cost ◽  
Tool Rotation

Incremental forming is an emerging technique for reducing the cost of tooling, increasing the flexibility and reducing the thermal energy usage in forming of thermoplastic polymer surfaces. This paper examines the effect of Single Point Incremental Forming (SPIF) on the mechanical properties of a semi-crystalline Polyamide (Nylon 66) material. The effects of incremental depth and tool rotation speed on these properties, and on the sheet temperature during forming are quantified. Differential Scanning Calorimetry and X-ray Diffraction are performed to understand changes in crystallinity and chain orientation of the polymer due to SPIF. It is found that the formed material has a substantial higher toughness and ductility, but reduced yield stress and Young’s modulus, as compared to the formed material. Stress relaxation tests show similar relaxation behavior for the formed and unformed polymer. The effect of SPIF on the chain orientation and its link to the mechanical properties are discussed.

Hot Single Point Incremental Forming of Ti-6Al-4V Alloy

2014 ◽  
Vol 611-612 ◽  
pp. 1079-1087 ◽  
Author(s):  
Mikel Ortiz ◽  
Mariluz Penalva ◽  
Mildred J. Puerto ◽  
Petr Homola ◽  
Václav Kafka
Keyword(s):  
Mechanical Properties ◽  
Room Temperature ◽  
Incremental Forming ◽  
Single Point ◽  
Metal Alloy ◽  
Hot Forming ◽  
Lead Times ◽  
Single Point Incremental Forming ◽  
Aeronautical Industry ◽  
Reduction Of Costs

The lightweight metal alloy Ti-6Al-4V is widely used in the aeronautical industry due to its excellent mechanical properties. However, it is known the difficulty to deform Ti-6Al-4V sheets at room temperature because of its microstructure conditions. The present work focuses on the evaluation of formability of Ti-6Al-4V sheets using hot single point incremental forming (SPIF) process which it seems appropriate to produce small batches of parts due to its flexibility as it allows a significant reduction of costs and lead times. In order to characterize the SPIF of Ti-6Al-4V under hot forming conditions, a set of forming trials evaluation tests was carried out. The obtained results have allowed identifying the key process features and have demonstrated the potential of the proposed approach to hot form of small amounts of Ti-6Al-4V parts.

Influence of Single Point Incremental Forming on Mechanical Properties and Chain Orientation in Thermoplastic Polymers

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Mohammad Ali Davarpanah ◽  
Shalu Bansal ◽  
Rajiv Malhotra
Keyword(s):  
Mechanical Properties ◽  
Temperature Rise ◽  
Incremental Forming ◽  
Single Point ◽  
Degree Of Crystallinity ◽  
Single Point Incremental Forming ◽  
X Ray Diffraction ◽  
Scanning Calorimetry ◽  
Lower Yield Stress ◽  
Chain Orientation

Incremental forming of thermoplastic surfaces has recently received significant interest due to the potential for simultaneous reduction in thermal energy consumption and in part-shape specific tooling. This paper examines the mechanical properties and the chain orientation of the formed material in single point incremental forming (SPIF) of amorphous polyvinyl chloride (PVC) and semicrystalline polyamide sheets. Tensile and stress relaxation properties of the formed polymers are compared to those of the unformed polymer. The effect of incremental depth and tool rotation speed on the above properties, and on the temperature rise of the sheet during SPIF, is quantified. Differential scanning calorimetry (DSC) and X-ray diffraction (XRD) are used to compare the chain orientation and crystallinity of the formed and the unformed polymers. It is observed that the formed material has greater toughness and ductility, but lower yield stress and reduced Young's modulus, as compared to the unformed material. We also observe deformation-induced chain reorientation in the formed polymer, with minimal change in the degree of crystallinity. The link between the SPIF process parameters, temperature rise of the polymer during SPIF, change in chain orientation, and change in mechanical properties of the polymer is discussed.

scholarly journals Influence of Forming Parameters on the Mechanical Behavior of a Thin Aluminum Sheet Processed through Single Point Incremental Forming

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1461
Author(s):  
Muhammad Ilyas ◽  
Ghulam Hussain ◽  
Haris Rashid ◽  
Mohammed Alkahtani
Keyword(s):  
Mechanical Properties ◽  
Yield Strength ◽  
Residual Stresses ◽  
Strain Hardening ◽  
Incremental Forming ◽  
Single Point ◽  
Strain Hardening Exponent ◽  
Single Point Incremental Forming ◽  
Forming Parameters ◽  
Tool Diameter

Incremental sheet forming (ISF) is an economical process for batch production. This paper investigates post-forming mechanical properties with an emphasis on the relationship between residual stresses, strengths, micro-hardness and the strain-hardening exponent. Moreover, the influence of important process parameters on the post-forming tensile properties and hardness is analyzed. A Taguchi statistical analysis method is applied to study the effect of forming parameters and identify the best combinations to enhance the mechanical properties of the commercial aluminum. The results reveal that direct relationships exist for the plots of: (i) the strain-hardening exponent vs. the post-necking strain and (ii) difference of post-forming strengths vs. the strain-hardening exponent. Furthermore, the post-forming yield strength can be enhanced by 66.9% through the Single Point Incremental Forming (SPIF). Similarly, the ductility can be doubled by conducting the SPIF after performing the annealing of the as-received rolled sheet. In the present study, parts formed at a wall angle (θ) of 40° with a tool diameter (d) of 6 mm exhibit the highest strength. Moreover, most ductile parts will be obtained at ω = 1500 rpm, d = 22 mm and θ = 20°. It has also been shown that the compressive residual stresses are favorable for higher yield strength and improve hardness of the formed parts.

scholarly journals Interaction of Process Parameters, Forming Mechanisms, and Residual Stresses in Single Point Incremental Forming

Metals ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 656 ◽  
Author(s):  
Fabian Maaß ◽  
Marlon Hahn ◽  
A. Erman Tekkaya
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Process Parameters ◽  
Process Model ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Residual Stress State

The residual stress state of a sheet metal component manufactured by metal forming has a significant influence on the mechanical properties, and thus determines the time until the component fails, especially for dynamic loads. The origin of the resulting residual stress state of incrementally formed parts with regard to the forming mechanisms of shearing, bending, and the normal stress component is still under investigation. The relationship between the process parameters, the forming mechanisms, and the resulting residual stress state for a complex part geometry manufactured by single point incremental forming (SPIF) is presented in this publication. For this purpose, a validated numerical process model is used to analyze the influence of the step-down increment Δz for truncated cones on the characteristics of the forming mechanisms and the resulting residual stress state. For the first time the forming mechanisms are evaluated numerically on both sides of the formed component. A relationship between the process parameters, forming mechanisms, residual stresses, and the mechanical properties of an incrementally formed component is shown. Shearing-induced hardening is identified as a relevant influence on the residual stress state of cones.

Utilization of Wavy Toolpath in Single-Point Incremental Forming

2018 ◽  
Author(s):  
Tyler J. Grimm ◽  
Ihab Ragai ◽  
John T. Roth
Keyword(s):  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Final Part ◽  
Single Point Incremental Forming ◽  
Step Down ◽  
Material Forming ◽  
Surface Variability

Incremental forming (IF) is a sheet material forming method which utilizes a hemispherically tipped tool to form material. The tool is typically CNC controlled along a path which outlines the contours of the final geometry. The most common toolpaths used during forming are the spiral and step-down paths. Few variations of these toolpaths currently exist. A novel toolpathing strategy is proposed herein. This toolpath forms a wave-like path in order to mimic the effects of vibration-assisted tooling; however, with much greater control. A variation of this strategy in which the tool does not lose contact with the surface of the part throughout its path was tested. This method has been found to be an effective approach for improving the surface variability of the final part.

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