Review of the effect of process parameters on performance measures in the incremental sheet forming process

2020 ◽  
pp. 095440542096121
Author(s):  
Ashish Gohil ◽  
Bharat Modi
Keyword(s):  
Process Parameters ◽  
Metal Forming ◽  
Lead Time ◽  
Incremental Forming ◽  
Low Cost ◽  
Research Work ◽  
Sheet Forming ◽  
Commercial Production ◽  
Incremental Sheet Forming ◽  
Forming Process

Incremental sheet forming process has developed the interest of researchers in the field of sheet metal forming due to high formability and capability to produce prototypes of new products at low cost and minimum lead time. Research work is going on in various front to enhance the process capabilities so that it can be explored for commercial production. In this article, progress and recent development in the field of incremental forming has been reviewed and presented for the benefit of practicing engineers and industry. The effect of various process parameters on the performance of the process have been summarized in this paper. Moreover, the issues which need attention are discussed towards the conclusion of this paper.

A Mixed Toolpath Strategy for Improved Geometric Accuracy and Higher Throughput in Double-Sided Incremental Forming

2014 ◽  
Author(s):  
Rui Xu ◽  
Huaqing Ren ◽  
Zixuan Zhang ◽  
Rajiv Malhotra ◽  
Jian Cao
Keyword(s):  
Incremental Forming ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Recent Past ◽  
Forming Process ◽  
Process Flexibility ◽  
Formed Part ◽  
Future Work

Incremental sheet forming has attracted considerable attention in the recent past due to advantages that include high process flexibility and higher formability as compared to conventional forming processes. However, attaining required geometric accuracy of the formed part is one of the major issues plaguing this process. The Double-Sided Incremental Forming process has emerged as a potential process variant which can preserve the process flexibility while maintaining required geometric accuracy. This paper investigates a mixed toolpath for Double-Sided Incremental Forming which is able to simultaneously achieve good geometric accuracy and higher throughput than is currently possible. The geometries of parts formed using the mixed toolpath strategy are compared to the desired geometry. Furthermore, an examination of the forming forces is used to uncover the reasons for experimentally observed trends. Future work in this area is also discussed.

Modelling of the effects of process parameters on energy consumption for incremental sheet forming process

2020 ◽  
Vol 250 ◽  
pp. 119456 ◽  
Author(s):  
Fuyuan Liu ◽  
Xiaoqiang Li ◽  
Yanle Li ◽  
Zijian Wang ◽  
Weidong Zhai ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Process Parameters ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process

Parameter optimization and texture evolution in single point incremental sheet forming process

2019 ◽  
Vol 234 (1-2) ◽  
pp. 126-139 ◽  
Author(s):  
Shamik Basak ◽  
K Sajun Prasad ◽  
Amarjeet Mehto ◽  
Joy Bagchi ◽  
Y Shiva Ganesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Regression Models ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Input Process ◽  
Truncated Cone

Prototyping through incremental sheet forming is emerging as a latest trend in the manufacturing industries for fabricating personalized components according to customer requirement. In this study, a laboratory scale single-point incremental forming test setup was designed and fabricated to deform AA6061 sheet metal plastically. In addition, response surface methodology with Box–Behnken design technique was used to establish different regression models correlating input process parameters with mechanical responses such as angle of failure, part depth per unit time and surface roughness. Correspondingly, the regression models were implemented to optimize the input process parameters, and the predicted responses were successfully validated at the optimal conditions. It was observed that the predicted absolute error for angle of failure, part depth per unit time and surface roughness responses was approximately 0.9%, 4.4% and 6.3%, respectively, for the optimum parametric combination. Furthermore, the post-deformation responses from an optimized single point incremental forming truncated cone were correlated with microstructural evolution. It was observed that the peak hardness and highest areal surface roughness of 158 ± 9 HV and 1.943 μm, respectively, were found near to the pole of single-point incremental forming truncated cone, and the highest major plastic strain at this region was 0.80. During incremental forming, a significant increase in microhardness occurred due to grain refinement, whereas a substantial increase in the Brass and S texture component was responsible for the increase in the surface roughness.

Brass 70/30 and Incremental Sheet Forming Process

2013 ◽  
Vol 554-557 ◽  
pp. 1419-1431 ◽  
Author(s):  
Daniel Fritzen ◽  
Anderson Daleffe ◽  
Jovani Castelan ◽  
Lirio Schaeffer
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Cnc Machining ◽  
Forming Process ◽  
Wall Angle ◽  
Machining Center ◽  
Cad Cam ◽  
Cnc Machining Center

This work addresses through bibliographies and experiments the behavior of sheet brass 70/30 for Incremental Sheet Forming process - ISF, based on the parameters: wall angle (), step vertical (ΔZ) strategy and the way the tool. Experiments based on the method called Single Point Incremental Forming - SPIF. For execution of practical tests, we used the resources: software CAD / CAM, CNC machining center with three axles, matrix incremental, incremental forming tool and a device press sheets. Furthermore, measurement was made of the true deformation () and thickness (s1). Practical tests have shown that the spiral machining strategy yielded a greater wall angle, compared to the conventional strategy outline.

Investigating the Effect of Process Parameters in Incremental Sheet Forming Process

2021 ◽  
pp. 24-36
Author(s):  
Manish Oraon ◽  
Manish Kumar Roy ◽  
Vinay Sharma
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Batch Production ◽  
Force Microscopy ◽  
Atomic Force ◽  
Roughness Analysis ◽  
Step Down

Incremental sheet forming (ISF) is an emerging technique of sheet metal working that comes into the picture in the last two decades. The ISF involved the forming of shapes without using the dedicated dies. ISF is suitable for customized products, rapid prototyping, and low batch production. The study aims to investigate the effect of process parameters on the surface roughness. The experiments are conducted on aluminum AA3003-O grade with six parameters, and the trials are performed according to the design of experiment (DOE). The atomic force microscopy (AFM) technique is used for measuring the surface roughness. Analysis of variance (ANOVA) is used for analyzing the effect of process parameters in ISF. The result shows that the step-down size, feed rate of the tool, and wall angle are significant process parameter and their contributions for ISF are 85.86%, 1.12%, and 12.29%, respectively.

Numerical Simulation on the Effect of Process Parameters for Incremental Sheet Forming

2010 ◽  
Vol 97-101 ◽  
pp. 158-161 ◽  
Author(s):  
Qin Qin ◽  
Di Ping Wu ◽  
Mi Li ◽  
Yong Zang
Keyword(s):  
Process Parameters ◽  
Rapid Prototype ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Layered Manufacturing ◽  
Forming Process ◽  
Step Size ◽  
Flexible Technology ◽  
Vertical Step ◽  
Forming Angle

Incremental sheet forming (ISF), based on the ‘layered manufacturing’ principle of rapid prototype manufacturing technology, is an innovative and highly flexible technology for forming complex shaped parts without the need for costly dies. This paper presents a numerical investigation on the influence of forming process parameters by modeling the forming process. ANSYS/LS-DYNA has been used for the simulation. The results of study show that small vertical step size can improve the accuracy of the forming. Moreover, large forming angle can increase plastic strain and the four screwdown point optimization paths is an effective method to increase the accuracy of the formed sheet.

Asymmetric Incremental Sheet Forming

2005 ◽  
Vol 6-8 ◽  
pp. 35-58 ◽  
Author(s):  
J. Jeswiet
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Localized Deformation ◽  
Recent Advances ◽  
Conventional Spinning ◽  
Forming Methods

The use of computers in manufacturing has enabled the development of several new sheet metal forming processes. This paper describes modifications that have been made to traditional forming methods such as conventional spinning and shear forming, where deformation is localized. Recent advances have enabled this localized deformation to be accurately controlled and studied. Current developments have been focused on forming asymmetric parts using CNC technology, without the need for costly dies. Asymmetric Incremental Forming has the potential to revolutionize sheet metal forming, making it accessible to all levels of manufacturing.

scholarly journals Design and manufacturing of a fixing device for incremental sheet forming process

2018 ◽  
Vol 178 ◽  
pp. 02004 ◽  
Author(s):  
Daniel Nasulea ◽  
Gheorghe Oancea
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Incremental Forming ◽  
Single Point ◽  
Fem Simulation ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Design And Manufacturing

In incremental sheet forming processes, the expensive dedicated tool are avoided and replaced with a cheap and simple fixing device which support the sheet metal blanks. The current paper presents how a fixing device used for single point incremental forming device is designed, FEM simulated and manufactured. The fixing device can be used for parts with a cone frustum and pyramidal frustum made of DC05 deep drawing steel. The forces developed in the process and the device displacements were estimated using FEM simulation. The device components were manufactured using a CNC machines and the physical assembly is also presented in the paper.

Deformation Analysis of Multi-Stage Incremental Sheet Forming

2010 ◽  
Author(s):  
Zhen Cui ◽  
Feng Ren ◽  
Z. Cedric Xia ◽  
Lin Gao
Keyword(s):  
Incremental Forming ◽  
Numerical Study ◽  
Axial Direction ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Deformation Analysis ◽  
Conical Part ◽  
Forming Process ◽  
Deformation Kinetics ◽  
Deformation Mechanics

This paper presents an analytical and numerical study of deformation analysis for multistage incremental sheet forming processes, with a truncated conical part is used as an example. Unlike in the single-pass incremental forming where the sheet deformation is dominantly plane strain in the axial direction when forming a conical part, the sheet is also deformed in the circumferential direction when it is incrementally formed subsequently. Ideal deformation kinetics is assumed in the analytical derivations of strain distributions, which should be valid as long as the increment in deformation from one stage to the next is small. Numerical simulations with LS-DYNA are also conducted in an effort to understand the fundamental deformation mechanics of multistage incremental forming. The simulation result for a five-stage incremental forming process is presented. It is also used to correlate the analytical solution. An improved analytical equation for strain distributions is derived, which compares favorably with simulation results.

Application of ISF Process for the Throttle Pedal Fixed Plate

2013 ◽  
Vol 372 ◽  
pp. 450-453 ◽  
Author(s):  
Li Hua Li ◽  
Long Tao ◽  
Jin Wang ◽  
Cheng Zhao
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Industrial Applications ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Fixed Plate ◽  
Practical Procedure ◽  
Metal Forming Process ◽  
Suitable Process

Incremental Sheet Forming (ISF) is an emerging process. As a sheet metal forming process, it allows manufacturing components without the development of complex tools in comparison with stamping process. Although existing technical research achievements are plenty, it remains to be improved to make an industrially suitable process. This work is dedicated to the incremental forming of the throttle pedal fixed plate to analyze and figure out the reasonable practical procedure of ISF process, and helpful to promote the industrial applications of ISF.

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