scholarly journals Incremental forming using KUKA KR210-2 industrial robot - research regarding design rules and process modelling

2021 ◽  
Vol 343 ◽  
pp. 08005
Author(s):  
Alexandru Bârsan ◽  
Sever-Gabriel Racz ◽  
Radu Breaz
Keyword(s):  
Incremental Forming ◽  
Industrial Robot ◽  
Single Point ◽  
Process Modelling ◽  
Forming Process ◽  
Design Rules ◽  
Prototype Development ◽  
Small Series ◽  
Metal Forming Process ◽  
Combined Movements

Incremental sheet forming (ISF) process show a great potential in the manufacturing of small series production or prototype development parts. One of the sheet metal forming process, where the contact between punch and metal sheet is in a single point, is known as single point incremental forming (SPIF). The part is manufacture with a simple tool, known as punch, that performs a series of combined movements on the vertically and horizontally directions. The paper introduces a study regarding the design rules and process modelling of this unconventional process, by means of a KUKA KR210-2 industrial robot as technological equipment able to control the correlated movement of the punch. Supplementary, the design of the experimental layout, the process simulations and the singularity problems are considered.

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.

Improvement of Wall Angle in AISI 304 Stainless Steel Cup using Five Stage Single Point Incremental Forming

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
D. Suresh Kumar ◽  
N. Ethiraj
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Research Work ◽  
Single Stage ◽  
304 Stainless Steel ◽  
Forming Process ◽  
Wall Angle ◽  
Aisi 304 ◽  
Metal Forming Process ◽  
Stage Process

Incremental forming is a non-conventional metal forming process which is widely used to produce the customized parts especially in medical and aerospace industries. One of the challenges encountered in the single stage process is the maximum wall angle of the component that can be formed to a maximum possible depth without fracture. Many strategies have been tried by the researchers in the past to overcome this limitation. The aim of this research work is to investigate the effect of 5 stage incremental forming process in improving the formation of maximum wall angle to a possible height which is not possible in single stage incremental forming. Also, the different strain measurements are carried out to identify the region at which the fracture is likely to occur in the produced part. It is observed from single stage incremental forming process for a wall angle of 64, max. depth of 45mm is achieved in the part produced. The current 5 stage incremental forming process reached the max. height of 54 mm with a wall angle of 76 successfully. The maximum thickness strain of 75% is observed at a distance of 18mm from the bottom end of the flange of a formed component.

scholarly journals A Novel Machine-Learning-Based Procedure to Determine the Surface Finish Quality of Titanium Alloy Parts Obtained by Heat Assisted Single Point Incremental Forming

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1287
Author(s):  
Fernando Bautista-Monsalve ◽  
Francisco García-Sevilla ◽  
Valentín Miguel ◽  
Jesús Naranjo ◽  
María Carmen Manjabacas
Keyword(s):  
Machine Learning ◽  
Surface Finish ◽  
Incremental Forming ◽  
Single Point ◽  
Polynomial Kernel ◽  
Support Vector ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
And Performance

Single point incremental forming (SPIF) is a cheap and flexible sheet metal forming process for rapid manufacturing of complex geometries. Additionally, it is important for engineers to measure the surface finish of work pieces to assess their quality and performance. In this paper, a predictive model based on machine learning and computer vision was developed to estimate arithmetic mean surface roughness (Ra) and maximum peak to valley height (Rz) of Ti6Al4V parts obtained by SPIF. An image database was prepared to train different classification algorithms in accordance with a supervised learning approach. A speeded up robust feature (SURF) detector was used to obtain visual vocabulary so that the classifiers are able to group the photographs into classes. The experimental results indicated that the proposed predictive method shows great potential to determine the surface quality, as classifiers based on a support vector machine with a polynomial kernel are suitable for this purpose.

On the Effect of Curvature Radius on the Spif-Ability

2010 ◽  
Vol 129-131 ◽  
pp. 1222-1227 ◽  
Author(s):  
Ghulam Hussain ◽  
Gao Lin ◽  
Nasir Hayat ◽  
Asif Iqbal
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Curvature Radius ◽  
Single Point Incremental Forming ◽  
Test Results ◽  
Forming Process ◽  
Wall Angle ◽  
Metal Forming Process

Single Point Incremental Forming (SPIF) is a novel sheet metal forming process. The formability (i.e. spif-ability) in this process is determined through Varying Wall Angle Conical Frustum (VWACF) test. In this paper, the effect of variation in the curvature radius, a geometrical parameter of test, on the test results is investigated. A series of VWACF tests with a variety of curvature radii is performed to quantify the said effect. It is found that the spif-ability increases with increasing of curvature radius. However, any variation in the curvature radius does not affect the spif-ability when the normalized curvature radius (i.e. curvature radius/tool radius) becomes higher than 9.

Experimental Tests to Study Feasibility and Formability in Incremental Forming Process

2009 ◽  
Vol 410-411 ◽  
pp. 391-400 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Antonio Fiorentino ◽  
Luca Mazzoni ◽  
Claudio Giardini
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Experimental Tests ◽  
Final Part ◽  
Cnc Machine ◽  
Forming Process ◽  
Metal Forming Process ◽  
Sheet Formability

This paper deals with Incremental Sheet Forming (ISF), a sheet metal forming process, that knew a wide development in the last years. It consists of a simple hemispherical tool that, moving along a defined path by means of either a CNC machine or a robot or a self designed device, locally deforms a metal sheet. A lot of experimental and simulative researches have been conducted in this field with different aims: to study the sheet formability and part feasibility as a function of the process parameters; to define models able to forecast the final sheet thickness as a function of the drawing angle and tool path strategy; to understand how the sheet deforms and how formability limits can be defined. Nowadays, a lot of these topics are still open. In this paper, the results obtained from an experimental campaign performed to study sheet formability and final part feasibility are reported. The ISF tests were conducted deforming FeP04 deep drawing steel sheet 0.8 mm thick and analyzing the influence of the tool path strategy and of the adopted ISF technique (Single Point Incremental Forming Vs. Two Points Incremental Forming). The part feasibility and formability were evaluated considering final sheet thickness, geometrical errors of the final part, maximum wall angle and depth at which the sheet breaks. Moreover, process forces measurements were carried out by means of a specific device developed by the Authors, allowing to obtain important information about the load acting on the deforming device and necessary for deforming sheet.

Incremental Forming Process for the Accomplishment of Automotive Details

2007 ◽  
Vol 344 ◽  
pp. 559-566 ◽  
Author(s):  
A. Governale ◽  
A. Lo Franco ◽  
A. Panzeca ◽  
Livan Fratini ◽  
Fabrizio Micari
Keyword(s):  
Automotive Industry ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Innovation Process ◽  
Forming Process ◽  
Metal Forming Process ◽  
New Methodologies ◽  
Auto Body ◽  
Aluminium Sheets

In the last decades the scenario of the industrial production is remarkably changed, since new market requirements have to be faced by the industries. The market, actually, more and more, asks for vary models and niches product. The necessity to intercept dynamically and to satisfy the demands for the market, driver of the innovation process, involves the necessity to reduce the Timeto- market introducing to new methodologies of engineering, like the 3D-prototyping, for the qualitative and structural analysis of the final component. For these reasons, at the beginning of the nineties, a new philosophy of sheet metal forming process begins to assert on the industrial scene, whose basic logic is to obtain the shape wished through the progressive action of a tool of simple shape. In this job the application of the simplest process of incremental process on an industrial detail - famous in international field like SPIF (Single Point Incremental Forming) - will be described. The process is intrinsically flexible, and therefore is adapted to the rapid prototyping. The cases are still least, notice in the scientific literature, in which the details of industrial interest have been developed by Incremental Forming process; for this reason, the subject of this job is focused on the evaluation of the possibility to obtain real components of the automotive industry through the SPIF process. The job has been carried out in the R&D laboratory of "Fontana Pietro S.p.A.”, leader in the field of die manufacturing and stamping of component of the automotive industry. In particular, two parts of automotive auto body of aluminium sheets have been considered. It has been lead an analysis of technological and process feasibility, optimizing tool path considering experiences to obtain a product/process for the production of auto body prototypes.

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.

Deflection Compensations for Tool Path to Enhance Accuracy During Double-Sided Incremental Forming

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Lingam Rakesh ◽  
Srivastava Amit ◽  
N. V. Reddy
Keyword(s):  
Deformation Zone ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Sheet Plane ◽  
Support Tool ◽  
Metal Forming Process

Incremental sheet forming (ISF) is a flexible sheet metal forming process that enables forming of complex three-dimensional components by successive local deformations without using component-specific tooling. ISF is also regarded as a die-less manufacturing process in the absence of part-specific die. Geometric accuracy of formed components is inferior to that of their conventional counterparts. In single-point incremental forming (SPIF), the simplest variant of ISF, bending near component opening region is unavoidable due to lack of support. The bending in the component opening region can be reduced to a larger extent by another variant of ISF, namely, double-sided incremental forming (DSIF) in which a moving tool is used to support the sheet locally at the deformation zone. However, the overall geometry of formed components still has unacceptable deviation from the desired geometry. Experimental observation and literature indicate that the supporting tool loses contact with the sheet after forming certain depth. This work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflections due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap of deformation zone that occurs during forming (instead of using sine law). A number of examples are presented to show that the proposed methodology works for a variety of geometries (axisymmetric, varying wall angle, free-forms, features above and below initial sheet plane, and multiple features). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths using DSIF, and support tool maintains contact with sheet throughout the forming process.

Study of Tool Trajectory in Incremental Forming

2012 ◽  
Vol 472-475 ◽  
pp. 1586-1591 ◽  
Author(s):  
S.H. Wu ◽  
Ana Reis ◽  
F.M. Andrade Pires ◽  
Abel D. Santos ◽  
A. Barata da Rocha
Keyword(s):  
Damage Mechanics ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Continuum Damage Mechanics ◽  
Work Piece ◽  
Processing Parameter ◽  
Forming Process ◽  
Tool Paths ◽  
Metal Forming Process

Single point incremental forming (SPIF) is an innovative flexible sheet metal forming process which can be used to produce complex shapes from various materials. Due to its flexibility, it attracts a more and more attention in the recent decades. Several studies show that besides the major operating parameters, namely feed rate, tool radius, and forming speed etc., tool path is also an important processing parameter to affect the final forming component. In view of that, the present paper studies the influence of tool paths on the work piece quality by the finite element method coupled with the Continuum Damage Mechanics (CDM) model. The formability of incremental forming in different tool paths is also analyzed.

Sign in / Sign up

Export Citation Format

Share Document