Finite element investigation of some aspects affecting the depth and wall thickness of a part formed by single point incremental forming process

2012 ◽  
Vol 4 (4) ◽  
pp. 169
Author(s):  
Salah B.M. Echrif ◽  
Meftah Hrairi
Keyword(s):  
Finite Element ◽  
Wall Thickness ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process

Single-point incremental forming of sheet metals: Experimental study and numerical simulation

2016 ◽  
Vol 231 (2) ◽  
pp. 301-312 ◽  
Author(s):  
Matteo Benedetti ◽  
Vigilio Fontanari ◽  
Bernardo Monelli ◽  
Marco Tassan
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Incremental Forming ◽  
Single Point ◽  
Integration Scheme ◽  
Al Alloy ◽  
Single Point Incremental Forming ◽  
Sheet Metals ◽  
Forming Process ◽  
Starting Point

In this article, the single-point incremental forming of sheet metals made of micro-alloyed steel and Al alloy is investigated by combining the results of numerical simulation and experimental characterization, performed during the process, as well as on the final product. A finite element model was developed to perform the process simulation, based on an explicit dynamic time integration scheme. The finite element outcomes were validated by comparison with experimental results. In particular, forming forces during the process, as well as the final shape and strain distribution on the finished component, were measured. The obtained results showed the capability of the finite element modelling to predict the material deformation process. This can be considered as a starting point for the reliable definition of the single-point incremental forming process parameters, thus avoiding expensive trial-and-error approaches, based on extensive experimental campaigns, with beneficial effects on production time.

scholarly journals PROCESS SIMULATION AND QUALITY EVALUATION IN INCREMENTAL SHEET FORMING

2011 ◽  
Vol 12 (3) ◽  
Author(s):  
Meftah Hrairi ◽  
Salah B. M. Echrif
Keyword(s):  
Wall Thickness ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Low Cost ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Complex Parts

Single Point Incremental Forming (SPIF) is a promising sheet-metal-forming process that permits the manufacturing of small to medium-sized batches of complex parts at low cost. It allows metal forming to work in the critical ‘necking-to-tearing' zone which results in a strong thinning before failure if the process is well designed. Moreover, the process is complex due to the number of variables involved. Thus, it is not possible to consider that the process has been well assessed; several remaining aspects need to be clarified. The objective of the present paper is to study some of these aspects, namely, the phenomenon of the wall thickness overstretch along depth and the effect of the tool path on the distribution of the wall thickness using finite element simulations.Abstrak: Pembentukan Tokokan Mata Tunggal (Single Point Incremental Forming (SPIF)) merupakan satu proses pembentukan kepingan logam yang membolehkan pembuatan dalam jumlah yang kecil hingga sederhana, bahagian-bahagian yang kompleks pada kos yang rendah. Jika proses ini direka dengan baik, kaedah ini membolehkan pembentukan logam yang baik terhasil. Jika tidak, semasa peringkat zon kritikal ‘perleheran-ke-pengoyakan' menyebabkan penipisan keterlaluan yang boleh menyebabkan logam tersebut rosak. Tambahan pula, proses ini agak kompleks, kerana ia melibatkan beberapa pemboleh ubah. Maka, walaupun proses ini telah dinilaikan seeloknya; masih terdapat beberapa aspek lain yang perlu diperjelaskan. Objektif kertas ini dibentangkan adalah untuk mengkaji beberapa aspek tertentu, seperti, ketebalan dinding regangan berlebihan di sepanjang kedalaman dan kesan tool path (beberapa siri posisi koordinat untuk menentukan pergerakan alatan memotong ketika operasi memesin) terhadap pengagihan ketebalan dinding menggunakan simulasi unsur terhingga.

Geometry Compensation Methods for Increasing the Accuracy of the SPIF Process

2021 ◽  
Vol 883 ◽  
pp. 217-224
Author(s):  
Yannick Carette ◽  
Marthe Vanhulst ◽  
Joost R. Duflou
Keyword(s):  
Control Strategy ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Calculation Methods ◽  
Forming Process ◽  
Complex Deformation ◽  
Commercial Use ◽  
Compensation Methods ◽  
Deformation Mechanics

Despite years of supporting research, commercial use of the Single Point Incremental Forming process remains very limited. The promised flexibility and lack of specific tooling is contradicted by its highly complex deformation mechanics, resulting in a process that is easy to implement but where workpiece accuracy is very difficult to control. This paper looks at geometry compensation as a viable control strategy to increase the accuracy of produced workpieces. The input geometry of the process can be compensated using knowledge about the deformations occurring during production. The deviations between the nominal CAD geometry and the actual produced geometry can be calculated in a variety of different ways, thus directly influencing the compensation. Two different alignment methods and three deviation calculation methods are explained in detail. Six combined deviation calculation methods are used to generate compensated inputs, which are experimentally produced and compared to the uncompensated part. All different methods are able to noticeably improve the accuracy, with the production alignment and closest point deviation calculation achieving the best results

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.

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