Electrically Assisted Global Springback Elimination in AMS-T-9046 Titanium After Single Point Incremental Forming

Incremental Forming (IF) is a new type of sheet metal forming method being investigated by many because of its great potential in the manufacturing industry. The IF method forms sheet metal by use of a hemispherically shaped tool which follows a specified path that gradually forms the material as it traverses across the material. No dies are needed for this process, which is where the potential lies. IF is currently being researched in order to reduce the drawbacks of the process. These drawbacks include a maximum formable wall angle, degraded surface finish, low part accuracy, and local and global springback. This research focuses on the reduction of global springback, which arises from the stresses induced in the workpiece. This research approaches the problem with the use of electrical paths ran through the residual stress concentrations. The stress concentrations were mapped using Finite Element Analysis (FEA) and multiple tests were done to see which path had the greatest effect on springback. It was concluded that the best paths to apply electrical current through in order to reduce springback in an incrementally formed truncated pyramid are: along the formed corners from top to bottom, across the upper section of the formed corner, and along each side of the inner formed square. In addition, it was found that the path the electricity takes has a greater effect on the amount of springback reduction than the amount of paths applied. It is hypothesized that this is due to the stiffening effects of certain stresses.

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Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.783.148 ◽

2018 ◽

Vol 783 ◽

pp. 148-153

Author(s):

Muhammad Sajjad ◽

Jithin Ambarayil Joy ◽

Dong Won Jung

Keyword(s):

Mechanical Properties ◽

Sheet Metal ◽

Tool Path ◽

Incremental Forming ◽

Single Point ◽

Machining Process ◽

Machining Parameters ◽

Forming Process ◽

Element Analysis ◽

Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

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Application of Incremental Forming in Sheet Metal Bending Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.900.561 ◽

2014 ◽

Vol 900 ◽

pp. 561-564 ◽

Cited By ~ 2

Author(s):

Xiao Bing Dang ◽

Kai He ◽

Shu Guo Wei ◽

Jiu Hua Li ◽

Ru Xu Du

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Motion Control ◽

Sheet Metal ◽

Incremental Forming ◽

Single Point ◽

Element Analysis ◽

Motion Control Card ◽

Bending Process ◽

Sheet Metal Bending

Based on the thought of incremental forming, a new kind of sheet metal bending process has been described and investigated in this article. The software of the control system for the specific machine is developed combining motion control card and servo motors. Both single point and multi-points bending are taken into consideration from experimental and finite element analysis. Curved sheet and hyperbolic sheet metal are examined through experiments to extend the application for more smoothed and complicated curved sheet metal. The effectiveness of the process to deal with complex curved sheet metal is shown by all the experiments.

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The Effects of Polarity and Current Path in Electrically Assisted Single Point Incremental Forming of 2024-T3 Aluminum

Volume 1: Processes ◽

10.1115/msec2017-3037 ◽

2017 ◽

Cited By ~ 1

Author(s):

Tyler J. Grimm ◽

Ihab Ragai ◽

John T. Roth

Keyword(s):

Incremental Forming ◽

Single Point ◽

Negative Electrode ◽

Electrical Current ◽

Single Point Incremental Forming ◽

Direct Electrical Current ◽

Electrically Assisted ◽

Current Path ◽

Two Parameters ◽

Springback Reduction

Electrically assisted incremental sheet forming (EAIF) is a novel addition to the incremental forming (IF) method. One variation of this approach applies direct electrical current during forming. Many improvements over tradition IF can be seen by utilizing this method, to include greater part accuracy, reduced forming force, and greater formability. In order to maximize the effects of electrically assisted incremental forming, all parameters of the method must be investigated, including the polarity of the current passing through the part and the path that the applied current takes. The effects of altering these two parameters is the primary investigation in this research. It was determined that, in order to optimize springback reduction and formability during electrically assisted single point incremental forming, the tool should be assigned the positive electrode and the center of the workpiece should be assigned the negative electrode. Additionally, the mechanism behind the spalling effect inherent to EAIF is discussed.

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Comparison of incremental sheet metal forming process using newly designed multipoint tool with the existing single point tool by optimization and characterization methods on austenite stainless steel 202

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405420986098 ◽

2021 ◽

pp. 095440542098609

Author(s):

Ramkumar Kathalingam ◽

Baskar Neelakandan ◽

Elangovan Krishnan ◽

Sathiya Narayanan Chinnayan ◽

Selvarajan Arangulavan ◽

...

Keyword(s):

Surface Roughness ◽

Sheet Metal ◽

Sheet Metal Forming ◽

Metal Forming ◽

Incremental Forming ◽

Single Point ◽

Research Work ◽

Forming Process ◽

Wall Angle ◽

Incremental Sheet Metal Forming

Incremental Sheet metal Forming (ISF) is a reliable process of converting a blank to work piece with better outputs compared to conventional forming process. The flexibility of ISF in producing the rapid prototype based on the customer needs is increased which is also desirable in the industry. But Single Point Incremental Forming (SPIF) process takes more time to form a product and hence the longer time is a barrier in implementing this process in industries. In this research work, the ISF process was made on sheet metal SS 202 using a newly designed multi-point tool and the obtained outputs were compared with the same material of sheet metal formed by traditionally available single point tool. This Multi Point Incremental Forming (MPIF) process takes lesser process time to give better formability, improved wall angle and good surface roughness. The input process parameters selected for the process are type of tool, speed, feed, Vertical Step Depth (VSD), and lubrication. They are arranged by using the taguchi Design of Experiments (DOE) approach. The responses considered are wall angle, formability, surface roughness, spring back and forming time. The multiple outputs obtained were optimized by Grey Relational Analysis (GRA) to predict the superior parameter. Confirmation test was also made to validate the output result. Fractography analysis was carried out to predict the fracture mechanism obtained during the forming process. The surface topography was also made on the surface of the formed area of the sheet metal. This research work concludes that newly designed MPIF outperforms SPIF.

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The Effect of Multi-Point Electrical Paths on Global Springback Elimination in Single Point Incremental Forming

Volume 1: Processes ◽

10.1115/msec2017-3036 ◽

2017 ◽

Cited By ~ 1

Author(s):

Jacklyn Niebauer ◽

Derek Shaffer ◽

Ihab Ragai ◽

John T. Roth

Keyword(s):

Sheet Metal ◽

Incremental Forming ◽

Single Point ◽

High Stress ◽

High Stress Concentration ◽

Part Geometry ◽

Electrically Assisted ◽

Electrically Assisted Manufacturing ◽

Future Work ◽

Springback Reduction

Automotive and aerospace industries are interested in implementing die-less forming processes in order to reduce part costs and the required forming energy. One method of die-less forming is incremental forming, in which a sheet metal part is formed; typically with a hemispherical tool that deforms material as it pushes into the material and passes along the surface to create the desired part geometry. One problem with incremental forming is global springback, which occurs after the part has been formed and is released from the forming fixture. This effect is caused by residual stresses that are created during part deformation and result in geometric inaccuracies after the clamping force has been released. In this paper, the effect of post-deformation applied direct current on the springback of pre-formed sheet metal will be investigated. This is a process is a type of electrically assisted manufacturing (EAM). This paper is a continuation of previous works presented at MSEC 2015–2016. The initial feasibility study described herein already achieves a springback reduction of 26.3% and is dependent on the regions of high stress concentration as well as current density. Future work will extend this reduction through further testing of complex configurations.

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Asymmetric Single Point Incremental Forming of Sheet Metal

CIRP Annals ◽

10.1016/s0007-8506(07)60021-3 ◽

2005 ◽

Vol 54 (2) ◽

pp. 88-114 ◽

Cited By ~ 670

Author(s):

J. Jeswiet ◽

F. Micari ◽

G. Hirt ◽

A. Bramley ◽

J. Duflou ◽

...

Keyword(s):

Sheet Metal ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming

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Common defects of parts manufactured through single point incremental forming

MATEC Web of Conferences ◽

10.1051/matecconf/202134304007 ◽

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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