scholarly journals Hybrid Manufacturing of Stiffening Grooves in Additive Deposited Thin Parts

2021 ◽  
Vol 5 (4) ◽  
pp. 140
Author(s):  
Valentino A. M. Cristino ◽  
João P. M. Pragana ◽  
Ivo M. F. Bragança ◽  
Carlos M. A. Silva ◽  
Paulo A. F. Martins
Keyword(s):  
Stainless Steel ◽  
Analytical Model ◽  
Incremental Forming ◽  
Single Point ◽  
Groove Depth ◽  
Hybrid Manufacturing ◽  
Metal Parts ◽  
Steel Sheets ◽  
Tool Force ◽  
Good Agreement

This paper is focused on the hybridization of additive manufacturing with single-point incremental forming to produce stiffening grooves in thin metal parts. An analytical model built upon in-plane stretching of a membrane is provided to determine the tool force as a function of the required groove depth and to estimate the maximum allowable groove depth that can be formed without tearing. The results for additively deposited stainless-steel sheets show that the proposed analytical model can replicate incremental plastic deformation of the stiffening grooves in good agreement with experimental observations and measurements. Anisotropy and lower formability caused by the dendritic-based microstructure of the additively deposited stainless-steel sheets justifies the reason why the maximum allowable depth of the stiffening grooves is approximately 27% smaller than that obtained for the wrought commercial sheets of the same material that are used for comparison purposes.

A Dynamic Model for KUKA KR6 in SPIF Processes

2019 ◽  
Vol 957 ◽  
pp. 156-166 ◽  
Author(s):  
Mihai Crenganis ◽  
Akos Csiszar
Keyword(s):  
Dynamic Model ◽  
Model Validation ◽  
Incremental Forming ◽  
Industrial Robot ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Plastic Deformations ◽  
Metal Parts ◽  
Steel Sheets ◽  
Metal Sheets

The paper presents the development of a dynamic model for the KUKA KR6 robot during single point incremental forming (SPIF) of metal sheets. The dynamic model of the KUKA KR6 robot is created in MATLAB®-SimMechanics. This dynamic model is necessary to verify that the mechanical structure of this low payload industrial robot of 36 Kg capacity can withstand some specific forces in incremental forming of some low plasticity alloys like Ti6Al4V. In the Centre of Studies and Research for Plastic Deformations of "Lucian Blaga" University of Sibiu, different attempts on single point incremental forming of thin metal sheets have been carried out and some of the studies are based on SPIF using the KUKA KR6-2 industrial robot. Nevertheless, the previous experimental attempts using the KUKA KR 6-2 robot in SPIF processes were realised only on 0.4 mm thick DC04 steel sheets. This material has very good deformability properties and the forces during the process are relatively small. After the dynamic model validation some specific circular trajectories are imposed and the forces that can appear during SPIF process for Ti6Al4V alloy sheets are taken into consideration. After forces analysis, it was concluded that the KUKA KR6 robot can be used in single point incremental forming processes for metal parts requiring greater forming forces.

scholarly journals Characterisation of geometrical and physical properties of a stainless steel denture framework manufactured by single-point incremental forming

2021 ◽  
Vol 10 ◽  
pp. 605-623
Author(s):  
Mladomir Milutinović ◽  
Robert Lendjel ◽  
Sebastian Baloš ◽  
Danka Labus Zlatanović ◽  
Luka Sevšek ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Physical Properties ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming

Improving the Accuracy of Parts Manufactured by Single Point Incremental Forming

2013 ◽  
Vol 332 ◽  
pp. 443-448 ◽  
Author(s):  
Crina Radu ◽  
Ion Cristea ◽  
Eugen Herghelegiu ◽  
Stefan Tabacu
Keyword(s):  
Neural Network ◽  
Stainless Steel ◽  
Incremental Forming ◽  
Single Point ◽  
Optimization Methods ◽  
Single Point Incremental Forming ◽  
Surface Method ◽  
Good Ability ◽  
The Neural Network ◽  
Network Method

The aim of this paper is to enrich the knowledge related to the single point incremental forming (SPIF) process by evaluating the efficiency of two optimization methods - the response surface method and the neural network method - to improve the accuracy of manufactured parts by prescribing a proper combination of the process parameters. The analysis is performed for a double frustum of pyramid made by stainless steel. It was found a good ability of prediction of both methods, demonstrating their suitability for physical implementation in solving problems associated to the SPIF process.

scholarly journals Experimental Analysis of Single Point Incremental Forming of Truncated Cones in DC04 Steel Sheet

2020 ◽  
Vol 20 (4) ◽  
pp. 5-15
Author(s):  
B. Krasowski ◽  
A. Kubit ◽  
T. Trzepieciński ◽  
J. Slota
Keyword(s):  
Tool Path ◽  
Crack Formation ◽  
Incremental Forming ◽  
Single Point ◽  
Slope Angle ◽  
Frictional Resistance ◽  
Experimental Tests ◽  
Test Material ◽  
Synthetic Lubricant ◽  
Steel Sheets

AbstractExperimental tests to form truncated cones were carried out on a 3-axis milling machine. 0.8-mm thick low-alloy DC04 steel sheets were used as test material. The profile tool-path trajectory was generated using the EDGECAM software. The slope angle and diameter of the base of the conical shaped drawpieces were 70°-72° and 65 mm, respectively. The drawpiece heights were up to 75 mm. The full synthetic lubricant 75W85 was used to reduce the frictional resistance. The effect of selected incremental forming parameters on the formability of the DC04 sheet and the susceptibility to crack formation have been analysed and discussed. It was found that the surface roughness of the workpiece is strongly influenced by step depth. By controlling the feed rate, it is possible to prevent failure of the material.

Forming, fracture and corrosion behaviour of stainless steel 202 sheet formed by single point incremental forming process

2019 ◽  
Vol 6 (12) ◽  
pp. 126540 ◽  
Author(s):  
G Vignesh ◽  
C Sathiya Narayanan ◽  
C Pandivelan ◽  
K Shanmugapriya ◽  
Bhavishya Naik Tejavath ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Incremental Forming ◽  
Corrosion Behaviour ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process

Experimental Investigations and Numerical Analysis for Improving Knowledge of Incremental Sheet Forming Process for Sheet Metal Parts

2009 ◽  
Vol 623 ◽  
pp. 37-48 ◽  
Author(s):  
Steeve Dejardin ◽  
Jean Claude Gelin ◽  
Sebastien Thibaud
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Experimental Investigations ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Forming Strategy ◽  
Set Up

The paper is related to the analysis of shape distortions and springback effects arising in Single Point Incremental Forming. An experimental set up has been designed and manufactured to carry single point incremental forming on small size sheet metal parts. The experimental set up is mounted on 3-axes CNC milling machine tool and the forming tool is attached and move with the spindle. Experiments have been carried out on sheet metal parts to obtain tronconical shapes. The forming strategy associated to the movement of the forming tool has been also investigated. The experiments indicate that shape distortions arising in the corners of the tronconical shape are clearly related to forming strategy. The springback of rings cut in the tronconical parts have been also investigated. It is shown that positive or negative springback could be also related to forming strategy. In order to enhance experimental investigations, Finite Element simulations of the incremental sheet forming have been performed. Results obtained from the simulations prove that if boundary conditions and forming strategy carefully are taking into account, the finite elements results are in good agreement with experiments. So it is then possible to use FEM as a design tool for incremental sheet forming.

On a Simplified Model for the Tool and the Sheet Contact Conditions for the SPIF Process Simulation

2009 ◽  
Vol 410-411 ◽  
pp. 373-379 ◽  
Author(s):  
Camille Robert ◽  
Lanouar Ben Ayed ◽  
Arnaud Delamézière ◽  
Phillippe dal Santo ◽  
J.L. Batoz
Keyword(s):  
Incremental Forming ◽  
Large Strain ◽  
Single Point ◽  
Contact Interface ◽  
Forming Process ◽  
Contact Conditions ◽  
Simplified Approach ◽  
Contact Algorithm ◽  
Local Stresses ◽  
Good Agreement

The numerical simulation of the Single Point Incremental Forming process (SPIF) is time consuming due to the necessity to take into account various non-linearity such as the material behaviour, large strain deformation and the evolution of the tool-flange contact. Classical contact algorithms give good agreement with experimental results, but are time consuming. In this paper, we investigate the development of a procedure to simplify the management of the contact interface between the tool and the sheet. Nodes with imposed displacements are determined by a geometrical approximation of the deformed sheet. In order to have a better approximation of the local stresses in the flange, a pressure is applied on the tool side of the elements in the contact zone. The pressure value is obtained by an analytical model. A classical contact algorithm and the present simplified approach are compared in terms of an incremental forming benchmark. It has been shown that, for the benchmark problem studied here, a CPU time reduction of approximately 65% can be achieved while at the same time have good simulation results.

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