scholarly journals Influences of Vibration Parameters on Formability of 1060 Aluminum Sheet Processed by Ultrasonic Vibration-Assisted Single Point Incremental Forming

2019 ◽  
Vol 2019 ◽  
pp. 1-12
Author(s):  
Mingshun Yang ◽  
Lang Bai ◽  
Yan Li ◽  
Qilong Yuan
Keyword(s):  
Ultrasonic Vibration ◽  
Incremental Forming ◽  
Single Point ◽  
Aluminum Sheet ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Experimental Platform ◽  
Formed Part ◽  
Vibration Parameters ◽  
Forming Angle

With increasing design complexities of thin-walled parts, the requirement of enhanced formability has impeded the development of the single point incremental forming (SPIF) process. In the present research, the ultrasonic vibration-assisted single point incremental forming (UV-SPIF) method was introduced to increase the formability of sheet metals. AL1060 aluminum alloy was adopted as the experimental material, and a truncated cone part was considered as the research object. The simulation model of UV-SPIF was established to analyze the distribution of plastic strains in the formed part. A forming angle was selected as the measuring index of formability of the aluminum sheet, and the influences of different vibration parameters on formability were evaluated. An experimental platform was devised to verify the accuracy of the obtained simulation results. It was found that ultrasonic vibration effectively improved the forming limit of the sheet. When the amplitude was 6 µm and the frequency was 25 kHz, the sheet yielded the best formability with the largest forming angle of 67 degrees.

scholarly journals Research on the Radial Accuracy of Ultrasonic Vibration-Assisted Single Point Incremental Forming Parts

2019 ◽  
Vol 2019 ◽  
pp. 1-9
Author(s):  
Yang Mingshun ◽  
Bai Lang ◽  
Lin Yunbo ◽  
Li Yan ◽  
Yuan Qilong ◽  
...  
Keyword(s):  
Residual Stress ◽  
Ultrasonic Vibration ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Layer Spacing ◽  
Vibration Parameters ◽  
Error Generation ◽  
And Control

With the more and more complexity demands of the market, the geometric accuracy of the part has become the main factor restricting the development of single point incremental forming technology (SPIF). For this reason, with the truncated cone as the target part, the radial accuracy error generation mechanism was analyzed from the aspects of sheet springback and residual stress distribution. Four factors and three levels of surface response experiments were designed using the Box-Behnken Design (BBD) for tool head diameter, layer spacing, sheet thickness, and wall angle. The single and interactive influence law of the process parameters on the radial accuracy was obtained. In response to the above research results, the ultrasonic vibration was introduced into the process of SPIF to reduce springback by reducing residual stress. The influence of vibration parameters on the accuracy was obtained through experiments. The results showed that ultrasonic vibration could effectively improve and control the accuracy of the part.

Study on Forming Behaviour of Friction Stir Welded Blanks During Single Point Incremental Forming (SPIF) Process

2020 ◽  
Author(s):  
Shalin Marathe ◽  
Harit Raval
Keyword(s):  
Friction Stir Welding ◽  
Incremental Forming ◽  
Single Point ◽  
Base Material ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process ◽  
Friction Stir ◽  
Welding Processes

Abstract The automobile, transportation and shipbuilding industries are aiming at fuel efficient products. In order to enhance the fuel efficiency, the overall weight of the product should be brought down. This requirement has increased the use of material like aluminium and its alloys. But, it is difficult to weld aluminium using conventional welding processes. This problem can be solved by inventions like friction stir welding (FSW) process. During fabrication of product, FSW joints are subjected to many different processes and forming is one of them. During conventional forming, the formability of the welded blanks is found to be lower than the formability of the parent blank involved in it. One of the major reasons for reduction in formability is the global deformation provided on the blank during forming process. In order to improve the formability of homogeneous blanks, Single Point Incremental Forming (SPIF) is found to be giving excellent results. So, in this work formability of the welded blanks is investigated during the SPIF process. Friction Stir Welding is used to fabricate the welded blanks using AA 6061 T6 as base material. Welded blanks are formed in to truncated cone through SPIF process. CNC milling machine is used as SPIF machine tool to perform the experimental work. In order to avoid direct contact between weld seam and forming tool, a dummy sheet was used between them. As responses forming limit curve (FLC), surface roughness, and thinning are investigated. It was found that use of dummy sheet leads to improve the surface finish of the formed blank. The formability of the blank was found less in comparison to the parent metal involved in it. Uneven distribution of mechanical properties in the welded blanks leads to decrease the formability of the welded blanks.

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.

scholarly journals Study on Thickness Thinning Ratio of the Forming Parts in Single Point Incremental Forming Process

2018 ◽  
Vol 2018 ◽  
pp. 1-11 ◽  
Author(s):  
Mingshun Yang ◽  
Zimeng Yao ◽  
Yan Li ◽  
Pengyang Li ◽  
Fengkui Cui ◽  
...  
Keyword(s):  
Deformation Zone ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Feeding Speed ◽  
Forming Angle ◽  
Tool Diameter ◽  
Thinning Rate

An excessive thickness-reducing ratio of the deformation zone in single point incremental forming of the metal sheet process has an important influence on the forming limit. Prediction of the deformation zone thickness is an important approach to control the thinning ratio. Taking the 1060 aluminum as the research object, the principle of thickness deformation in the single point incremental forming process was analyzed; the finite element model was established using ABAQUS. A formula with high accuracy to predict the deformation zone thickness was fitted with the simulation results, and the influences of process parameters, such as tool diameter, step down, feeding speed, sheet thickness, and forming angle, on thinning ratio were analyzed. The accuracy of the finite element simulation was verified by experiment. A method to control the thinning rate by changing the forming trajectory was proposed. The results showed that the obtained value by using the fitted formula is closer to the experimental results than that obtained by the sine theorem. The thinning rate of the deformation zone increases with the increase of tool diameter, forming angle, and sheet thickness and decreases with the increase of step down, while the feeding speed had no significant effect on the thinning ratio. The most important factor of the thinning ratio is the forming angle, and the thinning ratio can be effectively reduced by using the forming trajectory with a uniformly distributed pressing point.

Manufacture of Accurate Titanium Cranio-Facial Implants with High Forming Angle Using Single Point Incremental Forming

2013 ◽  
Vol 549 ◽  
pp. 223-230 ◽  
Author(s):  
Joost R. Duflou ◽  
Amar Kumar Behera ◽  
Hans Vanhove ◽  
Liciane S. Bertol
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Design Feature ◽  
Feature Analysis ◽  
Medical Applications ◽  
Single Point Incremental Forming ◽  
Wall Angle ◽  
Titanium Grade ◽  
Intermediate Part ◽  
Forming Angle

One of the key application areas of Single Point Incremental Forming is in the manufacture of parts for bio-medical applications. This paper discusses the challenges associated with the manufacture of cranio-facial implants with extreme forming angles using medical grade titanium sheets. While on one hand, the failure wall angle is an issue of concern, the parts also need to be manufactured with accuracy at the edges where the implants fit into the human body. Systematic steps taken to overcome these challenges, using intelligent intermediate part design, feature analysis and compensation, are discussed. A number of case studies illustrating the manufacture of accurate parts in aluminium, stainless steel and titanium grade-2 alloy are discussed.

Experimental Study on Residual Formability of Single Point Incrementally Formed Part

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Conventional Process

Abstract A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

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