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

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.

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

Advances in Materials Science and Engineering ◽

10.1155/2019/8405438 ◽

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.

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

Advances in Materials Science and Engineering ◽

10.1155/2018/2927189 ◽

2018 ◽

Vol 2018 ◽

pp. 1-11 ◽

Cited By ~ 2

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.

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Forming mechanisms-related residual stress development in single point incremental forming

Production Engineering ◽

10.1007/s11740-018-0867-3 ◽

2018 ◽

Vol 13 (2) ◽

pp. 149-156 ◽

Cited By ~ 3

Author(s):

F. Maaß ◽

M. Hahn ◽

A. E. Tekkaya ◽

M. Dobecki ◽

A. Poeche ◽

...

Keyword(s):

Residual Stress ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming ◽

Stress Development

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Ultrasonic vibration-assisted single point incremental forming of hemispherical shape using multi-stage forming strategy

International Journal of Mechatronics and Manufacturing Systems ◽

10.1504/ijmms.2020.10033392 ◽

2020 ◽

Vol 13 (3) ◽

pp. 247

Author(s):

Kaushik M. Patel ◽

Bharat A. Modi ◽

Ashish M. Gohil

Keyword(s):

Ultrasonic Vibration ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming ◽

Multi Stage ◽

Forming Strategy

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Study on Process Parameters on Single Point Incremental Forming of PVC

Materials Science Forum ◽

10.4028/www.scientific.net/msf.878.74 ◽

2016 ◽

Vol 878 ◽

pp. 74-80 ◽

Cited By ~ 4

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.

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Study the Effect of Multilayer Single Point Incremental Forming on Residual Stresses for Bottom Plates

Al-Khwarizmi Engineering Journal ◽

10.22153/kej.2017.02.004 ◽

2017 ◽

Vol 13 (3) ◽

pp. 99-107

Author(s):

Aseel Hamad Abed ◽

Aqeel Sabree Bedan ◽

Mohanad Faeq Noori

Keyword(s):

Residual Stresses ◽

Incremental Forming ◽

Single Point ◽

Important Task ◽

Bottom Plate ◽

Single Point Incremental Forming ◽

Production Operation ◽

Single Plate ◽

And Control

Abstract Knowing the amount of residual stresses and find technological solutions to minimize and control them during the production operation are an important task because great levels of deformation which occurs in single point incremental forming (SPIF), this induce highly non-uniform residual stresses. In this papera propose of a method for multilayer single point incremental forming with change in thickness of the top plate (0.5, 0.7, 0.9) mm and lubrication or material between two plates(polymer, grease, grease with graphite, mos2) to knowing an effect of this method and parameters on residual stresses for the bottom plates. Also compare these results for the bottom plates with the single plate at same thickness 0.9 mm.The results showed that when increase thickness of the top plate the value of residual stresses will decrease for bottom plates and when used graphite with grease between two plates gives less residual stresses (R.S = 60.173 MPa.) reverse when used Mos2 which will gives a larger residual stresses (R.S = 146.617 MPa.) in the bottom plate. Keywords: Multilayer Single Point Incremental Forming (SPIF), Residual Stresses, Lubrication.

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STUDY ON FORMING FORCES OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING WITH DUMMY SHEET

Journal of Manufacturing Engineering ◽

10.37255/jme.v4i3pp120-128 ◽

2019 ◽

Vol 14 (3) ◽

Author(s):

Vikas Sisodia ◽

Shailendra Kumar

Keyword(s):

Process Parameters ◽

Feed Rate ◽

Incremental Forming ◽

Single Point ◽

Sheet Thickness ◽

Single Point Incremental Forming ◽

Forming Force ◽

Step Size ◽

Wall Angle ◽

Influence Of Process Parameters

The present paper describes the experimental investigation on influence of process parameters on maximum forming force in Single Point Incremental Forming (SPIF) process using dummy sheet. Process parameters namely dummy sheet thickness, tool size, step size, wall angle and feed rate are selected. Taguchi L18 orthogonal array is used to design the experiments. From the analysis of variance (ANOVA) dummy sheet thickness, tool size, step size and wall angle are significant process parameters while feed rate is insignificant. It is found that as dummy sheet thickness, tool size, step size and wall angle increase magnitude of peak forming force increases while there is marginal decrease in forming force as feed rate increases. Predictive model is also developed for forming force. Validation tests are performed in order to check the accuracy of developed model. Optimum set of process parameters is also determined to minimize forming force. Experimental results are in good agreement with results predicted by the developed mathematical model.

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