Heat Assisted Single Point Incremental Forming of Polymer Sheets

2016 ◽  
Author(s):  
Shubhamkar Kulkarni ◽  
Vijay Sarthy Mysore Sreedhara ◽  
Gregory Mocko
Keyword(s):  
Room Temperature ◽  
Incremental Forming ◽  
Single Point ◽  
Future Research ◽  
Single Point Incremental Forming ◽  
Thermoplastic Polymer ◽  
Localized Deformation ◽  
Hot Air ◽  
Polymer Sheets ◽  
Complex Shapes

The objective of this research is to study the improvement in the formability of thermoplastics using heat assisted single point incremental forming. Single point incremental forming is a production process for forming sheet materials without the use of dedicated tooling (dies/molds). The process is an alternative to thermoforming for low volume forming of sheets. It involves forming the final shape through a series of localized incremental deformations. It has been observed that heat assisted techniques have shown an improvement in the formability limits for sheet metals. In this research, this concept has been tested for improving the formability of polymer sheets. Hot air us used to increase the temperature within a localized region in front of the tool. A single point incremental forming device is modified through the development of a specialized tool holder and nozzle which heats the polymer sheet to temperatures higher than the room temperature but below the glass transition temperature of the polymer and applies the forming loads. The results from the experiments are summarized as: i) the formability angle increases of polystyrene from 27 degrees to 46 degrees when comparing room temperature forming to forming at an elevated temperature (170°F–180 °F), ii) a reduction in the forces needed for forming is observed qualitatively, and iii) the surface finish on the formed parts do not show visible change. This demonstrates promise of manufacturing complex shapes from thermoplastic polymer sheets using heat assisted incremental forming. Future research includes 1) simulating the localized deformation of the material to enable process planning, 2) quantifying the forming forces and heat control of the system, and 3) exploring the manufacturing technique to other materials.

Development of Magnetic Field-Assisted Single-Point Incremental Forming

2021 ◽  
Vol 883 ◽  
pp. 189-194
Author(s):  
Marco Gucciardi ◽  
Derrick Benson ◽  
Livan Fratini ◽  
Gianluca Buffa ◽  
Hitomi Yamaguchi
Keyword(s):  
Magnetic Field ◽  
Magnetic Force ◽  
Incremental Forming ◽  
Single Point ◽  
Vertical Direction ◽  
Aluminum Sheet ◽  
Single Point Incremental Forming ◽  
Vertical Load ◽  
Localized Deformation ◽  
Physical Interference

Single Point Incremental Forming (SPIF) has recently introduced the concept of material formability enhancement through localized deformation. Since material is processed by means of a pin tool attached to spindle, physical interference (especially in vertical direction) limits attainable shapes with the conventional process. The aim of the following work is to increase the variety of achievable geometries with SPIF through in-process magnetic field assistance. An innovative configuration managing SPIF tool movement using magnetic force is proposed. With this in mind, a magnet configuration was designed to generate a vertical load able to plastically deform a 0.5 mm thick AA1100 aluminum sheet. Experiments were carried out to prove the concept by manufacturing a truncated cone; the results demonstrated the feasibility of Magnetic Field-Assisted SPIF.

Effect of Incremental Depth and Part Shape on Failure Modes in Single Point Incremental Forming of Polymers

2015 ◽  
Author(s):  
Mohammad Ali Davarpanah ◽  
Rajiv Malhotra
Keyword(s):  
Failure Modes ◽  
Incremental Forming ◽  
Single Point ◽  
Rate Of Change ◽  
Single Point Incremental Forming ◽  
Wall Angle ◽  
Cold Forming ◽  
Modes Of Failure ◽  
Polymer Sheets ◽  
Significant Research

Single Point Incremental Forming (SPIF) has received considerable attention recently due to advantages such as part-shape-independent tooling, higher formability and higher process flexibility as compared to conventional forming. While significant research has been performed on SPIF of metals, recent work has also shown the feasibility of using SPIF for cold-forming of thermoplastic polymer sheets. However, the effects of incremental depth and part shape on the modes of failure during polymer SPIF have rarely been investigated. This paper examines the effects of part shape and incremental depth on the formability and failure modes in polymer SPIF. It is shown that greater incremental depths result in greater formability in polymer SPIF. Furthermore, it is shown that increasing the rate of change of the wall angle with the Z depth of the part increases the maximum formability achievable using a given incremental depth. At the same time, it is observed that this dual advantage of greater formability and reduced forming time, possible with higher incremental depths, is limited by the occurrence of sheet wrinkling when the incremental depth becomes too high. Additionally, the dependence of sheet wrinkling on the overall shape of the part being formed is also shown.

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.

Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

2020 ◽  
Vol 38 (8A) ◽  
pp. 1137-1142
Author(s):  
Baqer A. Ahmed ◽  
Saad K. Shather ◽  
Wisam K. Hamdan
Keyword(s):  
Vickers Hardness ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Coil Current ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

Multiobjective optimization of process variables in single-point incremental forming using grey relational analysis coupled with entropy weights

2021 ◽  
pp. 146442072110204
Author(s):  
Abdulmajeed Dabwan ◽  
Adham E Ragab ◽  
Mohamed A Saleh ◽  
Atef M Ghaleb ◽  
Mohamed Z Ramadan ◽  
...  
Keyword(s):  
Grey Relational Analysis ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Process Variables ◽  
Relational Analysis ◽  
Grey Relational

Incremental sheet forming is a specific group of sheet forming methods that enable the manufacture of complex parts utilizing computer numerical control instead of specialized tools. It is an incredibly adaptable operation that involves minimal usage of sophisticated tools, dies, and forming presses. Besides its main application in the field of rapid prototyping, incremental sheet forming processes can be used for the manufacture of unique parts in small batches. The goal of this study is to broaden the knowledge of the deformation process in single-point incremental forming. This work studies the deformation behavior in single-point incremental forming by experimentally investigating the principal stresses, principal strains, and thinning of single-point incremental forming products. Conical-shaped components are fabricated using AA1050-H14 aluminum alloy at various combinations of fundamental variables. The factorial design is employed to plan the experimental study and analysis of variance is conducted to analyze the results. The grey relational analysis approach coupled with entropy weights is also implemented to identify optimum process variables for single-point incremental forming. The results show that the tool diameter has the greatest effect on the thinning of the SPIF product, followed by the sheet thickness, step size, and feed rate.

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