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

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.

Surface Roughness in Incremental Sheet Metal Forming of AA5052

2013 ◽  
Vol 753-755 ◽  
pp. 203-206 ◽  
Author(s):  
On Uma Lasunon
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Feed Rate ◽  
Metal Forming ◽  
Single Point ◽  
Forming Process ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming ◽  
Depth Increment

This paper presents the effect of forming parameters on the arithmetic mean surface roughness (Ra) of aluminum alloy built by a single-point incremental sheet metal forming process. Three investigated parameters are feed rate (12.5, 25 and 50 in/min), depth increment (0.015 and 0.030 in), and wall angle (45° and 60°). The results show that wall angle, depth increment and its interaction play an important role on the surface roughness, while feed rate has little effect. The optimal forming conditions for minimum surface roughness are feed rate of 25 in/min, depth increment of 0.015 in and wall angle of 45°.

Formability and Surface Finish Studies in Single Point Incremental Forming

2011 ◽  
Author(s):  
A. Bhattacharya ◽  
Samarjit Singh ◽  
K. Maneesh ◽  
N. Venkata Reddy ◽  
Jian Cao
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Surface Finish ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Experimental Results ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming ◽  
Tool Diameter

Incremental sheet metal forming (ISMF) has demonstrated its great potential to form complex three-dimensional parts without using a component specific tooling. The die-less nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet parts. However, ISMF has limitations with respect to maximum formable wall angle, geometrical accuracy and surface finish of the component. In the present work, an experimental study is carried out to study the effect of incremental sheet metal forming process variables on maximum formable angle and surface finish. Box-Behnken method is used to design the experiments for formability study and full factorial method is used for surface finish study. Analysis of experimental results indicates that formability in incremental forming decreases with increase in tool diameter. Formable angle first increases and then decreases with incremental depth and it is also observed that the variation in the formable angle is not significant in the range of incremental depths considered to produce good surface finishes during the present study. A simple analysis model is used to estimate the stress values during incremental sheet metal forming assuming that the deformation occurs predominantly under plane strain condition. A stress based criterion is used along with the above mentioned analysis to predict the formability in ISMF and its predictions are in very good agreement with the experimental results. Surface roughness decreases with increase in tool diameter for all incremental depths. Surface roughness increases first with increase in incremental depth up to certain angle and then decreases. Surface roughness value decreases with increase in wall angle.

Compensations for Tool Path to Enhance Accuracy During Double Sided Incremental Forming

2015 ◽  
Author(s):  
Rakesh Lingam ◽  
Anirban Bhattacharya ◽  
Javed Asghar ◽  
N. Venkata Reddy
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Incremental Sheet Metal Forming

Incremental Sheet Metal Forming (ISMF) is a flexible sheet metal forming process that enables forming of complex three dimensional components by successive local deformations without using component specific tooling. ISMF is also regarded as die-less manufacturing process and in the absence of part-specific dies, geometric accuracy of formed components is inferior to that of their conventional counterparts. In Single Point Incremental Forming (SPIF), the simplest variant of ISMF, bending near component opening region is unavoidable due to lack of support. The bending in the component opening region can be reduced to a larger extent by another variant of ISMF namely Double Sided Incremental Forming (DSIF) in which a moving tool is used to support the sheet locally at the deformation zone. However the overall geometry of formed components still has unacceptable deviation from the desired geometry. Experimental observation and literature indicates that the supporting tool loses contact with the sheet after forming certain depth. Present work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflection due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap that occurs during forming (instead of using sine law). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths.

Formability and Surface Finish Studies in Single Point Incremental Forming

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
A. Bhattacharya ◽  
K. Maneesh ◽  
N. Venkata Reddy ◽  
Jian Cao
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Surface Finish ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Experimental Results ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming ◽  
Tool Diameter

Incremental sheet metal forming (ISMF) has demonstrated its great potential to form complex three-dimensional parts without using a component specific tooling. The die-less nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet parts. However, ISMF has limitations with respect to maximum formable wall angle, geometrical accuracy, and surface finish of the component. In the present work, an experimental study is carried out to study the effect of incremental sheet metal forming process variables on maximum formable angle and surface finish. Box–Behnken method is used to design the experiments for formability study and full factorial method is used for surface finish study. Analysis of experimental results indicates that formability in incremental forming decreases with increase in tool diameter. Formable angle first increases and then decreases with incremental depth and it is also observed that the variation in the formable angle is not significant in the range of incremental depths considered to produce good surface finishes during the present study. A simple analysis model is used to estimate the stress values during incremental sheet metal forming assuming that the deformation occurs predominantly under plane strain condition. A stress-based criterion is used along with the above mentioned analysis to predict the formability in ISMF and its predictions are in very good agreement with the experimental results. Surface roughness decreases with increase in tool diameter for all incremental depths. Surface roughness increases first with increase in incremental depth up to certain angle and then decreases. Surface roughness value decreases with increase in wall angle.

Preliminary Studies on the Determination of FLD for Single Point Incremental Sheet Metal Forming

2012 ◽  
Vol 504-506 ◽  
pp. 863-868 ◽  
Author(s):  
Miklos Tisza ◽  
Péter Zoltán Kovács ◽  
Zsolt Lukács
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
New Technologies ◽  
Single Point ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Forming Limit ◽  
Incremental Sheet Metal Forming

Development of new technologies and processes for small batch and prototype production of sheet metal components has a very important role in the recent years. The reason is the quick and efficient response to the market demands. For this reasons new manufacturing concepts have to be developed in order to enable a fast and reliable production of complex components and parts without investing in special forming machines. The need for flexible forming processes has been accelerated during the last 15 years, and by these developments the technology reaches new extensions. Incremental sheet metal forming (ISMF) may be regarded as one of the promising developments for these purposes. A comprehensive research work is in progress at the University of Miskolc (Hungary) to study the effect of important process parameters with particular emphasis on the shape and dimensional accuracy of the products and particularly on the formability limitations of the process. In this paper, some results concerning the determination of forming limit diagrams for single point incremental sheet metal forming will be described.

scholarly journals Effect of Process Parameters and Preheating Temperature on Surface Roughness and Thickness Distribution in Hole Flanging using Incremental Sheet Metal Forming

2019 ◽  
Vol 8 (12S2) ◽  
pp. 84-87
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Thickness Distribution ◽  
Research Work ◽  
Preheating Temperature ◽  
Incremental Sheet Metal Forming ◽  
Best Parameter ◽  
Hole Flanging

Incremental Sheet metal forming is a die less method of forming which offers high formability. In this research work; effect of step depth, tool rotation speed and preheating temperature on surface roughness and thinning of flange wall is investigated in hole flanging using incremental forming. The parameter optimization is carried out by Taguchi method. Grey relational analysis is carried out to obtain best parameter combination.

scholarly journals Influence of process parameters on surface roughness and forming time of Al-1100 sheet in incremental sheet metal forming

2019 ◽  
Vol 13 (2) ◽  
pp. 4911-4927
Author(s):  
Swagatika Mohanty ◽  
Srinivasa Prakash Regalla ◽  
Yendluri Venkata Daseswara Rao
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Sheet Metal ◽  
Process Parameters ◽  
Sheet Metal Forming ◽  
Feed Rate ◽  
Metal Forming ◽  
Wall Angle ◽  
Surface Method ◽  
Incremental Sheet Metal Forming

Product quality and production time are critical constraints in sheet metal forming. These are normally measured in terms of surface roughness and forming time, respectively. Incremental sheet metal forming is considered as most suitable for small batch production specifically because it is a die-less manufacturing process and needs only a simple generic fixture. The surface roughness and forming time depend on several process parameters, among which the wall angle, step depth, feed rate, sheet thickness, and spindle speed have a greater impact on forming time and surface roughness. In the present work, the effect of step depth, feed rate and wall angle on the surface roughness and forming time have been investigated for constant 1.2 mm thick Al-1100 sheet and at a constant spindle speed of 1300 rpm. Since the variable effects of these parameters necessitate multi-objective optimization, the Taguchi L9 orthogonal array has been used to plan the experiments and the significance of parameters and their interactions have been determined using analysis of variance (ANOVA) technique. The optimum response has been brought out using response surfaces. Finally, the findings of response surface method have been validated by conducting additional experiments at the intermediate values of the parameters and these results were found to be in agreement with the predictions of Taguchi method and response surface method.

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.

On the Effect of Curvature Radius on the Spif-Ability

2010 ◽  
Vol 129-131 ◽  
pp. 1222-1227 ◽  
Author(s):  
Ghulam Hussain ◽  
Gao Lin ◽  
Nasir Hayat ◽  
Asif Iqbal
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Curvature Radius ◽  
Single Point Incremental Forming ◽  
Test Results ◽  
Forming Process ◽  
Wall Angle ◽  
Metal Forming Process

Single Point Incremental Forming (SPIF) is a novel sheet metal forming process. The formability (i.e. spif-ability) in this process is determined through Varying Wall Angle Conical Frustum (VWACF) test. In this paper, the effect of variation in the curvature radius, a geometrical parameter of test, on the test results is investigated. A series of VWACF tests with a variety of curvature radii is performed to quantify the said effect. It is found that the spif-ability increases with increasing of curvature radius. However, any variation in the curvature radius does not affect the spif-ability when the normalized curvature radius (i.e. curvature radius/tool radius) becomes higher than 9.

New Method for Blank Expansion of Rectangular Box

2011 ◽  
Vol 308-310 ◽  
pp. 1004-1007
Author(s):  
Liu Ru Zhou ◽  
Hai Ming Wan
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Apex Angle ◽  
Forming Limit ◽  
Forming Process ◽  
Incremental Sheet Metal Forming ◽  
Planning Experiment

The principle of NC incremental sheet metal forming as well as the process planning, experiment of the square conical box forming are presented. Because the deformation of sheet metal only occurs around the tool head and the deformed region is subjected to stretch deformation and thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheet metal deformation. The sine law indicates that the thickness of the square conical box wall is close to zero when the half-apex angle of the square conical box wall is close to zero. Therefore, we must know the forming limit half-apex angle to ensure that the forming can be carried out successfully, i.e., to ensure that the deformed region with a certain thickness will not fracture. It will succeed in square conical box incremental forming in a single tool-path if the forming is carried out with an angle which is larger than the forming limit half-apex angle. The fracture in the forming component can be avoided by these methods. A square conical box of uniform wall-thickness can be formed by NC incremental forming process. The thickness of deformation area is increased by increasing half-apex angle. The wrinkle in the forming component can be avoided by these methods.

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