scholarly journals Parameter optimization for deformation energy and forming quality in single point incremental forming process using response surface methodology

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771011 ◽  
Author(s):  
Zimeng Yao ◽  
Yan Li ◽  
Mingshun Yang ◽  
Qilong Yuan ◽  
Pengtao Shi
Keyword(s):  
Surface Roughness ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Deformation Energy ◽  
Geometric Error ◽  
Forming Process ◽  
Wall Angle ◽  
Forming Quality ◽  
Step Down

The deformation energy in single point incremental forming has an immediate impact on the processing cost, the heat and the wear effects between the tool and the formed material. Meanwhile, poor forming quality is still one of the largest challenges for the development and commercialization of this method. Therefore, the goal of this study is to search for the optimal working condition for lower energy consumption with better forming quality during the forming process. A Box–Behnken design for a cone parts forming process has been performed. The effects of four input parameters (step down, tool diameter, wall angle, and initial sheet thickness) on three outputs—deformation energy, surface roughness, and geometric error—have been investigated. With the target of minimal synchronization of deformation energy consumption, surface roughness, and geometric error, which are 1522.4 J, 0.97 µm, and 1.939 mm, respectively, in this case, four processing parameters were optimized with tool diameters as 16 mm, step down as 0.5 mm, sheet thickness as 0.57 mm, and wall angle as 65°. With optimization of deformation energy and surface roughness, in conjunction with geometric error compensation, an increased accuracy of the resulting parts can be obtained with minimum deformation energy and surface roughness.

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.

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.

Experimental and Simulation Study of Single Point Incremental Forming of Polycarbonate

2019 ◽  
Author(s):  
Saurabh Rai ◽  
Rakesh Kumar ◽  
Harish Kumar Nirala ◽  
Kevin Francis ◽  
Anupam Agrawal
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Material Strength ◽  
Displacement Curve ◽  
Single Point Incremental Forming ◽  
Aircraft Industry ◽  
Forming Process ◽  
Wall Angle ◽  
Safety Glass ◽  
Force Displacement

Abstract Single point incremental forming (SPIF) is more accurate and economical than the conventional forming process for customized products. Majority of the work in SPIF has been carried out on metals. However, polymers are also required to shape. Polycarbonate has wide application in safety glass, bottles, automotive and aircraft industry due to its transparent as well as attractive processing and mechanical properties as compared to other polymeric plastics. In present work, the Polycarbonate (PC) sheet of thickness 1.8 mm is deformed to make a square cup at different angles. Tensile testing is done to analyze the effect of wall angle on the deformed cup. This work illustrates the effect of the SPIF process on material strength in a different directions (vertical and horizontal) of the final deformed product. Tool forces are evaluated using ABAQUS® simulation for SPIF. Numerical simulation approach is used to calculate the fracture energy, which utilizes the force-displacement curve of the specimen and is verified.

Improvement of Wall Angle in AISI 304 Stainless Steel Cup using Five Stage Single Point Incremental Forming

2020 ◽  
Vol 12 (1) ◽  
Author(s):  
D. Suresh Kumar ◽  
N. Ethiraj
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Research Work ◽  
Single Stage ◽  
304 Stainless Steel ◽  
Forming Process ◽  
Wall Angle ◽  
Aisi 304 ◽  
Metal Forming Process ◽  
Stage Process

Incremental forming is a non-conventional metal forming process which is widely used to produce the customized parts especially in medical and aerospace industries. One of the challenges encountered in the single stage process is the maximum wall angle of the component that can be formed to a maximum possible depth without fracture. Many strategies have been tried by the researchers in the past to overcome this limitation. The aim of this research work is to investigate the effect of 5 stage incremental forming process in improving the formation of maximum wall angle to a possible height which is not possible in single stage incremental forming. Also, the different strain measurements are carried out to identify the region at which the fracture is likely to occur in the produced part. It is observed from single stage incremental forming process for a wall angle of 64, max. depth of 45mm is achieved in the part produced. The current 5 stage incremental forming process reached the max. height of 54 mm with a wall angle of 76 successfully. The maximum thickness strain of 75% is observed at a distance of 18mm from the bottom end of the flange of a formed component.

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.

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

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.

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.

Experimental Tests to Study Feasibility and Formability in Incremental Forming Process

2009 ◽  
Vol 410-411 ◽  
pp. 391-400 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Antonio Fiorentino ◽  
Luca Mazzoni ◽  
Claudio Giardini
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Experimental Tests ◽  
Final Part ◽  
Cnc Machine ◽  
Forming Process ◽  
Metal Forming Process ◽  
Sheet Formability

This paper deals with Incremental Sheet Forming (ISF), a sheet metal forming process, that knew a wide development in the last years. It consists of a simple hemispherical tool that, moving along a defined path by means of either a CNC machine or a robot or a self designed device, locally deforms a metal sheet. A lot of experimental and simulative researches have been conducted in this field with different aims: to study the sheet formability and part feasibility as a function of the process parameters; to define models able to forecast the final sheet thickness as a function of the drawing angle and tool path strategy; to understand how the sheet deforms and how formability limits can be defined. Nowadays, a lot of these topics are still open. In this paper, the results obtained from an experimental campaign performed to study sheet formability and final part feasibility are reported. The ISF tests were conducted deforming FeP04 deep drawing steel sheet 0.8 mm thick and analyzing the influence of the tool path strategy and of the adopted ISF technique (Single Point Incremental Forming Vs. Two Points Incremental Forming). The part feasibility and formability were evaluated considering final sheet thickness, geometrical errors of the final part, maximum wall angle and depth at which the sheet breaks. Moreover, process forces measurements were carried out by means of a specific device developed by the Authors, allowing to obtain important information about the load acting on the deforming device and necessary for deforming sheet.

The Effect of Lubricants and Material Properties in Surface Roughness and Formability for Single Point Incremental Forming Process

2014 ◽  
Vol 979 ◽  
pp. 359-362
Author(s):  
Nuttaphong Sornsuwit ◽  
Sunthorn Sittisakuljaroen
Keyword(s):  
Surface Roughness ◽  
Adhesive Wear ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Sheet Surface ◽  
Air Blowing ◽  
Asymmetric Shape ◽  
High Roughness

The single point incremental forming (SPIF) is a manufacturing process which allows small batch and asymmetric shape fabrication. The research focuses on its applications by consider surface roughness and formability. The surface roughness of specimen was resulted by the influence obtained between tool and specimen, where the lubricant played a significant role during the forming process, as well as material elongation as a mechanical property governed the formability of metal sheet. Surface roughness tester, SEM, EDS and profilometer were used for the characterizations. The results showed that low roughness value (Ra) of SUS 304 and SUS 316L obtained by applying air blowing as a lubricant, while Ti Gr2 could obtain low roughness by using MoS2. The behavior of wear was an adhesive wear which transfer to an abrasive wear. SUS 304 and SUS 316L sheet of test specimens achieved higher depth in forming by air lubricant and MoS2, and Ti Gr2 sheet revealed a better formability with MoS2. Furthermore, the highest depth was correlated with high roughness value for each material.

The Influence of Temperature on Secondary Forming of Titanium Gr 2 Sheet by Use of Single Point Incremental Forming

2014 ◽  
Vol 979 ◽  
pp. 351-354
Author(s):  
Nuttaphong Sornsuwit ◽  
Sunthorn Sittisakuljaroen
Keyword(s):  
Surface Roughness ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Stress Relieving ◽  
Different Temperatures ◽  
Influence Of Temperature On ◽  
Metal Forming Process ◽  
High Flexibility

The single point incremental forming (SPIF) is a sheet metal forming process with high flexibility on manufacture of each individual workpiece. However, it usually requires more processing time than a conventional forming method and is important to process with appropriate parameters. This study is to investigate the influence of different temperatures on continuing secondary forming of Ti Gr2 sheet, employed the stress relieving and annealing temperature after primary forming. The deformed parts were examined on the following criteria; internal contact surface roughness, microhardness and sectional microstructure. Stress relieving and annealing temperatures of 580°C and 780°C were applied to the formed parts prior to their secondary forming. It is found that the surface roughness increased from Ra 2.104 μm and 2.498 μm to Ra 2.55 μm and 3.18 μm respectively after secondary forming. The formability of 25 mm radius test specimens remained at 12 mm depth with limited obvious change.

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