scholarly journals Investigation the Effect of Process Variables on the Formability of Parts Processed by Single Point Incremental Forming

2019 ◽  
Vol 14 (2) ◽  
pp. 58-70
Author(s):  
Adil Shbeeb Jabber
Keyword(s):  
Feed Rate ◽  
Metal Forming ◽  
Single Point ◽  
Effective Strain ◽  
Image Processing Technique ◽  
Cnc Machine ◽  
Forming Process ◽  
Step Size ◽  
Forming Angle ◽  
Incremental Step

Incremental sheet metal forming process is an advanced flexible manufacturing process to produce various 3D products without using dedicated tool as in conventional metal forming. There are a lot of process parameters that have effect on this process, studying the effect of some parameters on the strain distributions of the product over the length of deformation is the aim of this study. In order to achieve this goal, three factors (tool forming shape, feed rate and incremental step size) are examined depending on three levels on the strain distributions over the wall of the product. Strain measurement was accomplished by using image processing technique using MATALB program. The significance of the control factors are explored using two statistical methods:  analysis of variance (ANOVA) and main effect plot (MEP). All experiments were carried out on a sheet of Aluminum alloy (Al1050) with thickness 0.9 mm by using 3 axes CNC machine to produce frustum pyramid product. The result showed that the feed rate is a parameter that has large effect on the values of the effective strain percentage contribution of (42.86% and 51.42%), respectively, and is followed by step size (25.1% and 30.60%) percentage contributions and finally the tool shape with (21.79% and 10.54%) on the (55° and 45°) wall angle, respectively. The maximum and minimum average effective strain computed on the 55◦ forming angle were (0.580 and 0.399), respectively. Finally, the maximum and minimum average effective strain computed on the 45◦ forming angle were equal to (0.412 and 0.324), respectively.

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 Experimental Investigation and Optimal Prediction of Maximum Forming Angle and Surface Roughness of an Al/SUS Bimetal Sheet in an Incremental Forming Process Using Machine Learning

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4150
Author(s):  
Raneen Abd Ali ◽  
Wenliang Chen ◽  
M.S.H. Al-Furjan ◽  
Xia Jin ◽  
Ziyu Wang
Keyword(s):  
Machine Learning ◽  
Surface Roughness ◽  
Incremental Forming ◽  
Single Point ◽  
Continuous Variable ◽  
Gradient Boosting ◽  
Forming Process ◽  
Step Size ◽  
Forming Angle ◽  
Tool Diameter

Bimetal sheets have superior properties as they combine different materials with different characteristics. Producing bimetal parts using a single-point incremental forming process (SPIF) has increased recently with the development of industrial requirements. Such types of sheets have multiple functions that are not applicable in the case of monolithic sheets. In this study, the correlation between the operating variables, the maximum forming angle, and the surface roughness is established based on the ensemble learning using gradient boosting regression tree (GBRT). In order to obtain the dataset for the machine learning, a series of experiments with continuous variable angle pyramid shape were carried out based on D-Optimal design. This design is created based on numerical variables (i.e., tool diameter, step size, and feed rate) and categorical variable (i.e., layer arrangement). The grid search cross-validation (CV) method was used to determine the optimum GBRT parameters prior to model training. After the parameter tuning and model selection, the model with a better generalization performance is obtained. The reliability of the predictive models is confirmed by the testing samples. Furthermore, the microstructure of the aluminum/stainless steel (Al/SUS) bimetal sheet is analyzed under different levels of operating parameters and layer arrangements. The microstructure results reveal that severe cracks are attained in the case of a small tool diameter while a clear refinement is observed when a high tool diameter value with small step down is used for both Al and SUS layers.

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°.

Application of Response Surface Analysis and Genetic Algorithm for the Optimization of Single Point Incremental Forming Process

2013 ◽  
Vol 554-557 ◽  
pp. 1265-1272 ◽  
Author(s):  
Riadh Bahloul ◽  
Henia Arfa ◽  
Hedi Belhadj Salah
Keyword(s):  
Response Surface ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Step Size ◽  
Unknown Parameters ◽  
Forming Parameters ◽  
Tool Diameter ◽  
Incremental Step

Single point incremental forming (SPIF) is a modern method of forming sheet metal, where parts can be formed without the use of dedicated dies. The ability of SPIF to form a part is based on various forming parameters. Previous work was not accomplished with the help of design of experiments (DOE), thus reducing the number of parameters varied at any time. This paper presents a Box-Behnken experimental design, which develops the numerical plan, formalizes the forming parameters critical in SPIF and analyse data. The most critical factors affecting SPIF were found to be wall inclination angle, incremental step size, material thickness and tool size. The main effects of these parameters on the quality of the formed parts were studied in detail. Actually this work aims to “optimize the thinning rate and the maximum force by considering the tool diameter and the vertical pitch as unknown parameters for two different wall angles and thicknesses”. To this purpose, an optimization procedure based on the use of response surface methodology (RSM) and genetic algorithms (GA) have been proposed for application to find the optimum solutions. Finally, it demonstrated that the developed methods can solve high non-linear problems successfully. Associated plots are shown to be very efficient for a quick localization of the region of the search space containing the global optimum values of the SPIF parameters.

Improving Formability in SPIF Processes through High Speed Rotating Tool: Experimental and Numerical Analysis

2013 ◽  
Vol 549 ◽  
pp. 156-163 ◽  
Author(s):  
Gianluca Buffa ◽  
Davide Campanella ◽  
Rossano Mirabile ◽  
Livan Fratini
Keyword(s):  
High Speed ◽  
Single Point ◽  
Sheet Forming ◽  
Effect Of Temperature ◽  
Cnc Machine ◽  
Forming Process ◽  
New Approach ◽  
Process Mechanics ◽  
Forming Angle ◽  
Complex Parts

Single-point incremental forming (SPIF) is a quite new sheet-forming process which offers the possibility to deform complex parts without dedicated dies using a single-point tool and a standard three-axis CNC machine. Although the process mechanics enables higher strains with respect to traditional sheet-forming processes, research has been focused on further increasing the maximum forming angle. In the paper, a new approach is used to enhance the material formability through a localized sheet heating as a consequence of the friction work caused by high speed rotating tool. Numerical simulation was utilized to relate the effect of temperature with the main field variables distribution in the sheet.

Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

2020 ◽  
Vol 38 (8A) ◽  
pp. 1137-1142
Author(s):  
Baqer A. Ahmed ◽  
Saad K. Shather ◽  
Wisam K. Hamdan
Keyword(s):  
Vickers Hardness ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Coil Current ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

scholarly journals Common defects of parts manufactured through single point incremental forming

2021 ◽  
Vol 343 ◽  
pp. 04007
Author(s):  
Mihai Popp ◽  
Gabriela Rusu ◽  
Sever-Gabriel Racz ◽  
Valentin Oleksik
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Serial Robot ◽  
The Many ◽  
Cold Metal

Single point incremental forming is one of the most intensely researched die-less manufacturing process. This process implies the usage of a CNC equipment or a serial robot which deforms a sheet metal with the help of a relatively simple tool that follows an imposed toolpath. As every cold metal forming process, besides the many given advantages it has also some drawbacks. One big drawback in comparison with other cold metal forming processes is the low accuracy of the deformed parts. The aim of this research is to investigate the sheet metal bending mechanism through finite element method analysis. The results shows that the shape of the retaining rings has a big influence over the final geometrical accuracy of the parts manufactured through single point incremental forming.

A Research of the Precision of Titanium Sheet Formed by Hot Incremental Sheet Forming Method

2017 ◽  
Vol 749 ◽  
pp. 154-160
Author(s):  
Khanh Dien Le ◽  
Tan Hung Nguyen ◽  
Ngoc Huy Tran ◽  
Thanh Son Le ◽  
Huy Bich Nguyen ◽  
...  
Keyword(s):  
Empirical Process ◽  
Incremental Forming ◽  
New Technology ◽  
Single Point ◽  
Metal Sheet ◽  
Forming Process ◽  
Titanium Sheet ◽  
Metal Sheets ◽  
Experimental Process ◽  
Forming Angle

Single Point Incremental Forming (SPIF) is a recent technology of forming sheet in several decades. Nowadays, SPIF technology is still continued to be studied, applied and ameliorated in sheet manufacturing in industry. However one of the difficulties of the technology is the forming angle is still small (smaller than 800 according the properties of metal sheets). This paper recommends a measure of increasing the plasticity of the sheet by heating in time of forming by SPIF technology. Naturally, the plasticity of metal sheet increases by the temperature of the material in forming process with its limitation and constraint. The paper represents the effect of heating metal sheet through the empirical process of SPIF technology directed by the design of experiment (DOE). The analyses of the results of experimental process is applied to show the effect of heating to the precision of Titanium sheet. Finally, some private opinions about the heating in SPIF are also mentioned as a very tiny contribution of the research for the new technology.

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.

Single Point Incremental Forming Limits Using a Boxbehnken Design of Experiment

2007 ◽  
Vol 344 ◽  
pp. 629-636 ◽  
Author(s):  
M. Ham ◽  
J. Jeswiet
Keyword(s):  
Design Of Experiment ◽  
Incremental Forming ◽  
Single Point ◽  
Response Surfaces ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Forming Limits ◽  
Box Behnken Design ◽  
Five Factors ◽  
Incremental Step

Single Point Incremental Forming (SPIF) is a new method of forming sheet metal for which not all forming limits and forming parameters are yet completely understood. In this paper, a Box-Behnken design of experiment (DOE) is used to execute an experimental study used to determine the forming limits in Single Point Incremental Forming (SPIF). The Box-Behnken allows for good accuracy in defining a surface response for a relatively low number of experimental runs – hence its usefulness in experimental work. The Box-Behnken used in this paper solved five factors at three levels in forty six runs. The five factors analyzed are based on the most critical factors effecting SPIF; they are material type, material thickness, formed shape, tool size and incremental step size (depth of each step in form). The data resulting from the Box-Behnken progressed into graphical response surfaces; the response surfaces allow designers to determine what factors they need to select in order to successfully form a part using SPIF.

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