Effect of process parameters on formability in two-point incremental forming-machining of planar and twisted AA5083 blades

2022 ◽  
pp. 095440542110697
Author(s):  
Hossein Ghorbani-Menghari ◽  
Mehrdad Azadipour ◽  
Mehran Ghasempour-Mouziraji ◽  
Young Hoon Moon ◽  
Ji Hoon Kim
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Machining Process ◽  
Curved Surface ◽  
Forming Process ◽  
Forming Temperature ◽  
Feature Based ◽  
Tool Diameter

The deformation machining process (DMP) involves machining and incremental forming of thin structures. It can be applied for manufacturing products such as curved-surface blades without using 5-axis computerised numerical control machines. This work presents the effect of tool diameter and forming temperature on spring-back and dimensional accuracy of a simple fabricated part. The results of the first phase of the study are utilised to design the fabrication process of a curved surface blade. A feature-based algorithm is used to design the tool path for the forming process. The dimensional accuracy of the final product is improved through warm forming, two-point incremental forming, and extension of the bending zone to the outside of the product edges. The results show that DMP can be used to fabricate complex curved-surface workpieces with acceptable dimensional accuracy.

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

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.

scholarly journals Experimental Study the Effect of Tool Geometry on Dimensional Accuracy in Single Point Incremental Forming (SPIF) Process

2018 ◽  
Vol 21 (1) ◽  
pp. 108 ◽  
Author(s):  
Aqeel Sabree Bedan ◽  
Halah Ali Habeeb
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Tool Geometry ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Angle ◽  
Product Profile ◽  
Tool Diameter

Incremental forming is a flexible sheet metal forming process which performed by utilizes simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. One limitations of single point incremental forming (SPIF) process is the error occur between the CAD design and the product profile. This work presents the single point incremental forming process for produced pyramid geometry and studied the effect of tool geometry, tool diameter, wall angle, and spindle speed on the dimensional accuracy. Three geometries of forming tools were used in experimental work: ball end tool, hemispherical tool, and flat with round corner tool. The sheet material used was pure Aluminum (Al 1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The products dimensions were measured by utilized the dimensional sensor measuring instrument. The extracted results from the single point incremental forming process indicated the best acceptance between the CAD profile and product profile was found with the ball end tool and diameter of (10 mm), wall angle (50°) and the rotational speed of the tool was (800 rpm).

Deformations Limits Analysis of Sheet Metal Manufatured through the Incremental Forming Process

2017 ◽  
Vol 899 ◽  
pp. 272-277
Author(s):  
Hugo Dutra Gomes ◽  
Maria Carolina dos Santos Freitas ◽  
Luciano Pessanha Moreira ◽  
Flavia de Paula Vitoretti ◽  
Jose Adilson de Castro
Keyword(s):  
Mechanical Properties ◽  
Finite Element Method ◽  
Finite Element ◽  
Tool Path ◽  
Incremental Forming ◽  
Numerical Control ◽  
Tool Geometry ◽  
The Finite Element Method ◽  
Forming Process ◽  
Contact Conditions

The present study is primarily engaged in the implementation of the incremental stamping process in a computerized numeric control This paper presents two different approaches to this forming process, an experimental and other numerical. Experimental used by the computer numerical control to perform the printing process and performs numerical simulations of the process using the finite element method. Some parameters are analyzed in both approaches, such as product geometry effects, tool geometry, tool speed, tool path, contact conditions and mechanical properties of the materials.

scholarly journals An Investigation Study of Tool Geometry in Single Point Incremental Forming (SPIF) and their effect on Residual Stresses Using ANOVA Model

2019 ◽  
Vol 14 (2) ◽  
pp. 1-13
Author(s):  
Aqeel S Sabree Bedan ◽  
Halah Ali H Habeeb
Keyword(s):  
Residual Stresses ◽  
Rotational Speed ◽  
Incremental Forming ◽  
Single Point ◽  
Numerical Control ◽  
Tool Geometry ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Angle ◽  
Tool Diameter

Incremental forming is a flexible sheet metal forming process which is performed by utilizing simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. This work presents the single point incremental forming process for producing pyramid geometry and studies the effect of tool geometry, tool diameter, and spindle speed on the residual stresses. The residual stresses were measured by ORIONRKS 6000 test measuring instrument. This instrument was used with four angles of (0º,15º,30º, and 45º) and the average value of residual stresses was determined, the value of the residual stress in the original blanks was (10.626 MPa). The X-ray diffraction technology was used to measure the residual stresses. The sheet material used was Aluminum alloy (AL1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The extracted results from the single point incremental forming process were analyzed using analysis of variance (ANOVA) to predict the effect of forming parameters on the residual stresses. The optimum value of the residual stresses (55.024 MPa) was found when using the flat end with round corner tool and radius of (3 mm), wall angle of (55°) and a rotational speed of the tool of (800 rpm). The minimum value of the residual stresses (24.389MPa) was found when using hemispherical tool with diameter of (12 mm), wall angle of (45°) and a rotational speed of the tool of (800 rpm).  

A General Method of Numerical Simulation for Incremental Forming

2011 ◽  
Vol 403-408 ◽  
pp. 4084-4088
Author(s):  
Li Jun Chen ◽  
Geng Pei ◽  
Qing Bo Fang ◽  
Jun Jie Pan
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Axial Stress ◽  
Thickness Distribution ◽  
Three Dimensional ◽  
Element Model ◽  
Simulation Method ◽  
Numerical Control ◽  
Nc Code ◽  
Tool Diameter

This paper presents a general simulation method for sheet metal incremental forming(ISF). Firstly, a three-dimensional finite element model based on Dynaform was developed to simulate the process. The tool path during the process simulation was directly defined by numerical control (NC) code and so identical with that in operation. Then, the results of numerical simulations with different process parameters, such as tool diameter, depth increment and wall angle, were discussed in details. The simulations reveal that with the decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces and leads to thinning reduction and more uniform thickness distribution. In addition, as the definition of the tool path was in accord with the genuine motion trajectory of the tool, the results deduced from this model may be more precise compared with those from other previously simplified models.

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

A Novel Incremental Sheet Bending Process of Complex Curved Steel Plate

2017 ◽  
Vol 139 (11) ◽  
Author(s):  
Qiyang Zuo ◽  
Kai He ◽  
Xiaobing Dang ◽  
Wei Feng ◽  
Ruxu Du
Keyword(s):  
Tool Path ◽  
Numerical Control ◽  
Steel Plates ◽  
Work Piece ◽  
Forming Process ◽  
Shipbuilding Industry ◽  
Supporting System ◽  
Motion Modes ◽  
Bending Process ◽  
Curved Steel

Bending complex curved steel plates for constructing ship hull has long been a challenge in shipbuilding industry. This paper presents a novel incremental bending process to obtain complicated curved steel plates by a series of sequential and layered punches. Taking advantage of this process, the blank plate that is fixed and held by a flexible supporting system can incrementally be bent into the target shape by a press tool along a planned tool path step by step and layer by layer. Acting as a “lower die,” the flexible supporting system can provide flexible and multifunctional supports for the work piece during the forming process, whose four general motion modes are demonstrated in this paper. Meanwhile, the procedures of tool path planning and forming layering are also explained in detail. In addition, aiming at different motion modes of the flexible supporting system, two springback compensation methods are given. Furthermore, according to the forming principle presented in this paper, an original incremental prototype equipment was designed and manufactured, which is mainly composed of a three-axis computer numerical control (CNC) machine, a flexible supporting system, and a three-dimensional (3D) scanning feedback system. A series of forming experiments focusing on a gradual curvature shape were carried out using this prototype to investigate the feasibility and validity of this forming process.

Experimental Investigation of Single Point Incremental Forming of Aluminum Sheet in Groove Test

2017 ◽  
Vol 867 ◽  
pp. 177-183 ◽  
Author(s):  
Vikrant Sharma ◽  
Ashish Gohil ◽  
Bharat Modi
Keyword(s):  
Experimental Investigation ◽  
Incremental Forming ◽  
Single Point ◽  
Fractional Factorial ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Backing Plate ◽  
Groove Test ◽  
Factorial Design Of Experiments ◽  
Tool Diameter

Incremental sheet forming is one of the latest processes in sheet metal forming industry which has drawn attention of various researchers. It has shown improved formability compared to stamping process. Single Point Incremental Forming (SPIF) process requires only hemispherical tool and no die is required hence, it is a die-less forming process. In this paper experimental investigation on SPIF for Aluminium sheet has been presented. A groove test on Vertical Machining Centre has been performed. Factors (Step depth, Blank holder clamping area, Backing plate radius, Program strategy, Feed rate and Tool diameter) affecting the process are identified and experiments are carried out using fractional factorial design of experiments. Effect of the factors on fractured depth, forming time and surface finish have been analyzed using Minitab 17 software.

scholarly journals Simulation of incremental forming processes of a pyramidal ring made of two materials

2018 ◽  
Vol 19 (3) ◽  
pp. 313
Author(s):  
Masood Ghassabi ◽  
Milad Salimi ◽  
Mohammad Haghpanahi
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Cnc Machine ◽  
Forming Force ◽  
Forming Process ◽  
Dimensional Precision

Incremental forming is one of the most well-known forming processes for complex and asymmetric parts. This method uses a CNC machine, simple forming tool, and a die. This study focused on effects of some parameters such as the material, feed rate, pitch, rotational speed and movement strategy of tool on the dimensional precision, forming force, thickness distribution and fracture in the welding area. The results showed that single point incremental forming (SPIF) led to a better thickness distribution with lower tool force, whereas two-point incremental forming led to better dimensional accuracy. Rotational speed does not have any significant impact on the forming process while decreasing the feed rate partially reduced the forming force. According to the results, although dimensional precision in double point incremental forming is better than SPIF, when it comes to the thickness distribution, forming force, and economic issues, SPIF is in favor. The results also showed that by connecting two materials, different parameters for the two materials could be investigated simultaneously in one simulation process.

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.

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