scholarly journals Complexity-Based Analysis of the Effect of Forming Parameters on the Surface Finish of Workpiece in Single Point Incremental Forming (SPIF)

2021 ◽  
Vol 5 (4) ◽  
pp. 241
Author(s):  
Ali Akhavan Farid ◽  
Shin Shen Foong ◽  
Ondrej Krejcar ◽  
Hamidreza Namazi
Keyword(s):  
Manufacturing Industry ◽  
Complex Geometry ◽  
Incremental Forming ◽  
Fractal Theory ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Forming Parameters ◽  
Modern Manufacturing ◽  
The Relationship

Nowadays, the manufacturing industry is focused on newer modern manufacturing methods, such as single point incremental forming (SPIF). The popularity of the SPIF process in the manufacturing industry is increasing due to its capability for rapid prototyping, forming complex geometry with simple steps, and customizing products for customers. This study investigates the effect of forming parameters (feed rate and step size) on the surface structure of the aluminum AA6061 sheet. We employ fractal theory to investigate the complexity of deformed surfaces. Accordingly, we study the relationship between the complexity and roughness of the deformed surface. The results show that the complexity and roughness of the deformed surface vary due to the changes in forming parameters. Fractal analysis can be further employed in other manufacturing processes to investigate the relation between the complexity and roughness of processed surfaces.

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.

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.

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.

scholarly journals ANÁLISE EXPERIMENTAL DE ESTAMPABILIDADE DA CHAPA DE AÇO ASTM A653 DURANTE O PROCESSO DE ESTAMPAGEM INCREMENTAL POR PONTO ÚNICO E AVALIAÇÃO DA RUGOSIDADE IMPRESSA NA SUPERFÍCIE CONFORMADA

2021 ◽  
Vol 9 (209) ◽  
pp. 1-51
Author(s):  
Cleiton Ferreira
Keyword(s):  
Incremental Forming ◽  
True Strain ◽  
Single Point ◽  
Roughness Parameter ◽  
Incremental Sheet Forming ◽  
Surface Finishing ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Vertical Step ◽  
Incremental Step

This study aims to evaluate the behavior of ASTM A653 CS-A G90 steel in the process of Incremental Sheet Forming – ISF, based on the following parameters: diameter of the tool (Dt in mm) and the vertical step size between consecutive contours (∆z in mm). The experiments were based on a variation of the ISF process, called Single Point Incremental Forming - SPIF. In this study, seventeen tests were conducted using a punching tool with diameters (Dt ) of 5, 6 and 8 mm and vertical steps (∆z) of 0.4, 0.6 and 0.8 mm, intending to evaluate the true strain to the ISF process and the surface finishing measured by roughness parameter (Rz). Whereas, for the execution of practical testing, the resources used were a CNCmachining center with three axes, tools for incremental forming and a sheet-press device. As a result, greater depths were achieved using an incremental step of 0.4 mm. In additional tests, it came to attention that the diameter of the tool was also an important parameter when it is desired to increase the formability and greater depths are obtained when using small diameters. It can be observed yet, there is a tendency to increase the roughness parameter Rz when using greater vertical steps ∆z

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.

Single Point Incremental Forming Springback Reduction Using Edge Stiffener

2020 ◽  
Author(s):  
Tyler J. Grimm ◽  
Gowtham V. Parvathy ◽  
Laine Mears
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Back Side ◽  
Forming Process ◽  
Step Size ◽  
Elastic Deformations ◽  
Form Complex ◽  
Large Step ◽  
Large Step Size

Abstract Single point incremental forming (SPIF) is a dieless forming process which uses local deformations to form complex geometries. This is achieved through the use of a typically hemispherical tipped forming tool. Several variations of SPIF have been developed to improve the performance of this process. This includes the use of a partial die which is placed on the back-side of the material. The forming tool is then able to press the material into this partial die. Another method is to utilize a clamping fixture with a periphery that closely matches that of the desired geometry. While both of these methods improve the performance of SPIF, they also require dedicated fixturing. While these modifications still present an advantage over traditional stamping, it is desirable to avoid the use of any geometry-specific equipment. Springback is a significant issue when performing traditional SPIF. Springback can occur in two different ways: local and global. Local springback results from the elastic deformations created outside the region located directly beneath the forming tool. This causes poor accuracy as a result. Compensation methods have been developed to overcome this type of springback but are faced with certain limitations. Global springback refers to the springback experienced once the material is removed from its clamping fixture. This springback is a result of all residual stresses produced during forming. This springback is much more difficult to reduce and often requires annealing the workpiece subsequent to forming. A toolpath approach is explored herein as a method to reduce springback without the use of geometry-specific equipment. The toolpath developed begins at the edge of the clamping fixture, regardless of the geometry shape, and forms the flashing material prior to the desired geometry. By starting the toolpath along the edge of the fixture, elastic deformations are minimized. Additionally, the work hardening produced during this forming acts as a stiffener for the desired geometry, which behaves as a frame which matches the periphery of the desired geometry. This method was experimentally tested for its accuracy improvements when forming a truncated pyramid from 5052 aluminum. The angle of this stiffener, the step size of the stiffener, and the size of the desired geometry were varied. The fixture dimensions were held constant. This method was found to reduce the overall springback of the part and increase the accuracy of the resulting geometry. Furthermore, it was found that a large step size can be used to form the stiffener section of the part. By using a large step size, the time it takes to form this sacrificial region is minimized.

Recommendation of a Measure for Enhancing the Precision of Dimensions of Foil Products in Single Point Incremental Forming Technology

2015 ◽  
Vol 656-657 ◽  
pp. 479-483 ◽  
Author(s):  
Khanh Dien Le ◽  
Tan Hung Nguyen ◽  
Thien Binh Nguyen ◽  
Thanh Son Le ◽  
Huy Bich Nguyen ◽  
...  
Keyword(s):  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Technology ◽  
Sheet Materials ◽  
Forming Parameters ◽  
Plastic Materials ◽  
Almost All

Single Point Incremental Forming (SPIF) has become a popular technology of forming sheet materials in the recent decades. However, the springback phenomenon, an inborn property of almost all elasto-plastic materials, reduces the precision of dimensions of the products by the finished forming session. This paper attempts to find out a measure to minimize this unwanted obstacle by using both empirical and simulating methods in order to define the relations of springback values among the forming parameters such as diameter of the forming tool, its revolution per minute, its velocity and its feed rate. Analyzing these equations to extract the appropriate parameters of forming for enhancing the precision of SPIF products is the final aim of this paper.

Incrementally Formed Stiffeners Effect on the Reduction of Springback in 2024-T3 Aluminum After Single Point Incremental Forming

2015 ◽  
Author(s):  
Brandt J. Ruszkiewicz ◽  
Sean S. Dodds ◽  
Zachary C. Reese ◽  
John T. Roth ◽  
Ihab Ragai
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Stress Concentrations ◽  
Forming Process ◽  
Step Size ◽  
New Process ◽  
Geomagic Software ◽  
Truncated Pyramid ◽  
The Ideal

Single Point Incremental Forming (SPIF) is a relatively new process to form sheet metal. SPIF utilizes machines such as CNC’s and mills to form a part by making several spiraled passes, deforming the metal a certain distance, known as the step-size, with each pass. One major issue with this process is global springback. Once the metal is removed from its clamping fixture, the residual stresses that resulted from the forming process cause the material to springback. The purpose of this paper is to demonstrate how incrementally forming a stiffener on the outside of the desired geometry will manipulate the stress concentrations in the metal, and effectively reduce the amount of global springback that occurs after the specimen is unclamped from its fixture. For these tests, stiffeners were formed on the outside of a truncated pyramid; the material used for these test was 2024-T3 aluminum. After the work pieces were removed from their clamping fixtures, the amount of springback that they experienced was examined using Geomagic software to determine the ideal stiffener parameters for reducing global springback for a truncated pyramid in 2024-T3 aluminum.

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