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).

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).  

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.

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 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.

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.

Single Point Incremental Forming of Friction Stir Processed AA6063-O Alloy

2015 ◽  
Author(s):  
Senthil Kumar Velukkudi Santhanam ◽  
Vigneshwaran Ganesan ◽  
Subramanian Pillappan Shanmuganatan
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
High Capacity ◽  
Numerical Control ◽  
Special Technique ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Friction Stir ◽  
Increasing Demand

In the recent manufacturing trend and, in particular, in sheet metal forming, the requirement of customized production is still growing. Incremental forming is a special technique requiring no high capacity presses or set of dies, thus meeting the increasing demand for low volume production and rapid prototyping. The complex three dimensional parts of sheet metals are formed by the computer numerical control (CNC) movement of a simple generative hemispherical tool. In this paper, the single point incremental forming process is performed on friction stir processed AA 6063-O alloy. The process parameters for the experiment are taken based on L9 Orthogonal array. In this paper the maximum wall angle or the formability is investigated on a formed pyramid frusta. It is inferred that Friction stir process has improved the ductility of the aluminium alloy thus contributing to enhanced formability.

scholarly journals Study of the Effect of Process Parameters on Surface Profile Accuracy in Single-Point Incremental Sheet Forming of AA1050-H14 Aluminum Alloy

2020 ◽  
Vol 2020 ◽  
pp. 1-14
Author(s):  
Abdulmajeed Dabwan ◽  
Adham E. Ragab ◽  
Mohamed A. Saleh ◽  
Saqib Anwar ◽  
Atef M. Ghaleb ◽  
...  
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Surface Profile ◽  
Sheet Thickness ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Tool Diameter ◽  
Profile Accuracy

Single-point incremental forming is an innovative flexible and inexpensive technique to form sheet products when prototypes or small batches are required. The process allows complex geometries to be produced using a computer numerical control machine, eliminating the need for a special die. This study reports on the effects of four important single-point incremental forming process parameters on produced surface profile accuracies. The profile accuracy was estimated by measuring the side angle errors and surface roughness and also waviness and circularity of the product inner surface. Full factorial design of experiments was used to plan the study, and the analysis of variance was used to analyze and interpret the results. The results indicate that the tool diameter (d), step depth (s), and sheet thickness (t) have significant effects on the produced profile accuracy, while the feed rate (f) is not significant. As a general rule, thin sheets with greater tool diameters yielded the best surface quality. The results also show that controlling all surface quality features is complex because of the contradicting effects of, and interactions between, a number of the process parameters.

scholarly journals Achieving Accuracy Improvements for Single-Point Incremental Forming Process Using a Circumferential Hammering Tool

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 482
Author(s):  
Daniel Nasulea ◽  
Gheorghe Oancea
Keyword(s):  
Mathematical Models ◽  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Area ◽  
Forming Tools ◽  
Full Factorial

The paper presents a novel solution for improving the accuracy of the wall area of parts manufactured by single point incremental forming. Thus, a forming tool with a special design that works according to the principle of circumferential hammering is deployed, with a direct improving effect of the forming conditions and consequently of the dimensional accuracy of the part. The research is focused on an experimental study of frustum-of-cone shapes manufactured from sheet metal blanks of DC05 deep drawing steel of 1 mm thickness. A typical customary technological setup is used for the single point incremental forming process, without any additional elements, and two forming tools, a hemispherical and a special one, which use the circumferential hammering effect. Several preliminary tests using both tools were performed in order to prove that part accuracy can be significantly improved by using the circumferential hammering tool. The research was further expanded to investigate the influence on part wall dimensional accuracy of three factors: tool spindle speed, tool feed rate and part dimensional configuration. Using a full factorial plan of experiments the results of 32 test runs were processed. All parts were machined adequately, free of any material fracturing. Based on the achieved machining accuracy of the part walls, precision mathematical models were developed for the prediction of part dimensional accuracy in those areas. The mathematical models were validated by practice, as the predicted accuracies were matched by the experimental results.

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.

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