Design and manufacturing of an innovative rolling ball tool: A step forward towards the development of SPIF process

2022 ◽  
pp. 095440892110682
Author(s):  
M. Nikoueifar ◽  
A. Vaheb ◽  
M. Honarpisheh
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Optimal Conditions ◽  
Forming Force ◽  
Forming Process ◽  
Rolling Ball ◽  
New Class ◽  
Aluminum Sheets ◽  
Forming Technology ◽  
Design And Manufacturing

Incremental sheet forming (ISF) is an innovative forming technology which is widely used in various sectors of mechanical production. This is particularly useful for rapid prototyping and limited batch without a specific die. A new class of this method is single-point incremental forming (SPIF). This paper presents a comprehensive experimental investigation on the SPIF of Aluminum sheets, and, in particular, the influence of the forming tool is taken into account. A new rolling ball tool is designed to follow this, and the formability of the Aluminum sheets under the SPIF procedure is investigated for both new and conventional tools. Moreover, a number of important process parameters such as the feed rate, forming force, and surface roughness are considered in the experiments’ design. Finally, the optimal conditions in achieving a developed SPIF procedure in terms of the mentioned factors are reported and discussed. The findings of this work suggest that the surface quality after the forming process can be enhanced by 55% when using the new designed tool, while the forming force is reduced by 38% at the same time.

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.

Sheet Single Point Vibration Incremental Forming Process Simulation and Analysis of Process Parameters

2012 ◽  
Vol 430-432 ◽  
pp. 74-78 ◽  
Author(s):  
Gai Pin Cai ◽  
Cong Wen Xing ◽  
Zhi Hong Jiang ◽  
Zhong Kai Zhang
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Single Point ◽  
Product Yield ◽  
Simulation Software ◽  
Forming Force ◽  
Forming Process ◽  
Vibration Parameters ◽  
The Right ◽  
Theory Research

The deformation of vibration incremental forming process for sheet metal is in high complexity, theory research is not perfect. This subject using DEFORM simulation software, joined the vibration on the forming process of tool head and simulated the forming process base on different tool radius and vibration parameters. Simulation result indicated that vibration in greatly reduced the stress of the forming tool head. The right vibration parameters smoothed out the forming force largely, reduced sheet metal stress concentration, improved product quality and product yield. That has a higher degree of study and use value.

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.

Formability of Tailored Welded Blanks in Single Point Incremental Forming Process

2014 ◽  
Vol 979 ◽  
pp. 339-342 ◽  
Author(s):  
Kittiphat Rattanachan ◽  
K. Sirivedin ◽  
Chatchapol Chungchoo
Keyword(s):  
Laser Welding ◽  
Incremental Forming ◽  
Single Point ◽  
Weld Line ◽  
Welding Process ◽  
Metal Sheet ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Forming Technology ◽  
Dieless Forming

This paper is focused on single point incremental forming (SPIF) of a tailored welded blanks (TWBs) that produced by laser welding process. The SPIF process is a new dieless forming technology, which is a fast and economic solution to prototyping a metal sheet product. In the past, the SPIF researches carried out with the homogeneous metal sheet blank, but now a day, the demand of TWBs is still increased especially for an automotive industry. The aim of this research is to study the formability on the weld line of laser welding TWBs (SUS 304 and St 37) by the SPIF process.

Finite Element Modeling of Incremental Forming of Aluminum Sheets

2005 ◽  
Vol 6-8 ◽  
pp. 525-532 ◽  
Author(s):  
S. He ◽  
Albert Van Bael ◽  
Paul van Houtte ◽  
Joost R. Duflou ◽  
Alexander Szekeres ◽  
...  
Keyword(s):  
Finite Element ◽  
Complex Shape ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Strain History ◽  
Wall Angle ◽  
Aluminum Sheets ◽  
Forming Technology ◽  
Reaction Forces

Incremental forming is an innovative and flexible sheet metal forming technology for small batch production and prototyping, which does not require any dedicated die or punch to form a complex shape. This paper investigates the process of single point incremental forming of an aluminum cone with a 50-degree wall angle both experimentally and numerically. Finite element models are established to simulate the process. The output of the simulation is given in terms of final geometry, the thickness distribution of the product, the strain history and distribution during the deformation as well as the reaction forces. Comparison between the simulation results and the experimental data is made.

Locally Applied Direct Electric Current’s Effect on Springback of 2024-T3 Aluminum After Single Point Incremental Forming

2015 ◽  
Author(s):  
Brandt J. Ruszkiewicz ◽  
John T. Roth ◽  
David H. Johnson
Keyword(s):  
Residual Stresses ◽  
Electric Current ◽  
Incremental Forming ◽  
Single Point ◽  
Cnc Machine ◽  
Stress Concentrations ◽  
Forming Process ◽  
Tool Paths ◽  
Forming Technology ◽  
Exact Shape

Incremental forming is a sheet metal forming technology that utilizes a spherical tipped tool and a CNC machine to form a part through a series of spiraling tool paths. Springback is one of the largest concerns for incremental forming since a part can be the exact shape desired after forming until the part is unclamped from its forming fixtures, at which point it will springback due to the residual stresses resident in a part due to the forming process. This paper demonstrates how locally applied electric current can be utilized to reduce the springback due to residual stresses. The tests conducted in this paper demonstrate this concept via incrementally formed truncated-pyramid shapes that were formed from 2024-T3 aluminum. The residual stress concentration locations of the pyramid were determined using FEA. Direct electric current was locally applied to the stress concentrations of the pyramid prior to unclamping. Various current densities, time intervals, and electrical pulse locations were examined to find the ideal conditions for reducing springback for a tested geometry of 2024-T3 aluminum.

scholarly journals Influences of Process Parameters and Vibration Parameters on the Forming Force in the Ultrasonic-Assisted Incremental Forming Process

2018 ◽  
Vol 2018 ◽  
pp. 1-12 ◽  
Author(s):  
Lang Bai ◽  
Yan Li ◽  
Mingshun Yang ◽  
Zimeng Yao ◽  
Zhiyuan Yao
Keyword(s):  
Ultrasonic Vibration ◽  
Process Parameters ◽  
Single Point ◽  
Experimental Results ◽  
Forming Force ◽  
Forming Process ◽  
Layer Spacing ◽  
Forming Technology ◽  
Plastic Forming ◽  
Vibration Parameters

In the field of plastic forming, ultrasonic vibration has the advantages of small forming force and high forming quality, and it has been introduced into a single-point incremental plastic forming technique with high flexibility and high precision. The ultrasonic vibration single-point incremental compound forming technology with all the above advantages has been achieved. To reveal the variation tendency of the forming force under ultrasonic vibration and single-point incremental coupling, the process parameters (layer spacing, tool head radius, and feed rate) and vibration parameters (frequency and amplitude) on the forming force of the composite technology were quantitatively analyzed by theory, simulation, and experiment. The simulation and experimental results showed that ultrasonic vibration can significantly reduce the forming force of the composite technology. Compared with the simulation results, the theoretical results are not only closer to the experimental results but also have a shorter computation time and better prediction effect on the forming force. The change in the process parameters has a linear effect on the forming force, the nonlinearity of the vibratory parameters influences the forming force, and the frequencies and amplitudes in a suitable range allow the forming force to reach a minimum value. These conclusions have some significance for further studies on the ultrasonic vibratory single-point incremental composite forming technology.

Analysis of Lead Screw High-Speed Roll-Beating Forming

2010 ◽  
Vol 455 ◽  
pp. 151-155 ◽  
Author(s):  
Yan Li ◽  
L. Zhang ◽  
Ming Shun Yang ◽  
Qi Long Yuan
Keyword(s):  
Process Simulation ◽  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
The Self ◽  
Forming Process ◽  
Lead Screw ◽  
Forming Technology ◽  
Cold Roll ◽  
Simulation Results

Lead screw high-speed cold roll-beating is a new single-point incremental forming technology which is die-free and unconstrained. The principle of the forming process is analyzed. Modeling, meshing and parameter selecting for forming process simulation with ABAQUS are discussed. The lead screw cold roll-beating forming process simulation is carried out; stress & strain changes and metal flowing law are analyzed. Experiments are carried out with the self-developed experimental equipment. The experimental results are consistent with the simulation results, thus the validity of the simulation and feasibility of the forming process are verified.

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