scholarly journals Single-Point Incremental Forming of Titanium and Titanium Alloy Sheets

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6372
Author(s):  
Valentin Oleksik ◽  
Tomasz Trzepieciński ◽  
Marcin Szpunar ◽  
Łukasz Chodoła ◽  
Daniel Ficek ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Elevated Temperatures ◽  
Incremental Forming ◽  
Single Point ◽  
Production Costs ◽  
Electrical Heating ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Shape Accuracy

Incremental sheet forming of titanium and its alloys has a significant role in modern manufacturing techniques because it allows for the production of high-quality products with complex shapes at low production costs. Stamping processes are a major contributor to plastic working techniques in industries such as automotive, aerospace and medicine. This article reviews the development of the single-point incremental forming (SPIF) technique in titanium and its alloys. Problems of a tribological and microstructural nature that make it difficult to obtain components with the desired geometric and shape accuracy are discussed. Great emphasis is placed on current trends in SPIF of difficult-to-form α-, α + β- and β-type titanium alloys. Potential uses of SPIF for forming products in various industries are also indicated, with a particular focus on medical applications. The conclusions of the review provide a structured guideline for scientists and practitioners working on incremental forming of titanium and titanium alloy sheets. One of the ways to increase the formability and minimize the springback of titanium alloys is to treat them at elevated temperatures. The main approaches developed for introducing temperature into a workpiece are friction heating, electrical heating and laser heating. The selection of an appropriate lubricant is a key aspect of the forming process of titanium and its alloys, which exhibit unfavorable tribological properties such as high adhesion and a tendency to adhesive wear. A review of the literature showed that there are insufficient investigations into the synergistic effect of rotational speed and tool rotation direction on the surface roughness of workpieces.

scholarly journals Accuracy and Sheet Thinning Improvement of Deep Titanium Alloy Part with Warm Incremental Sheet-Forming Process

2021 ◽  
Vol 5 (4) ◽  
pp. 122
Author(s):  
Badreddine Saidi ◽  
Laurence Giraud Moreau ◽  
Abel Cherouat ◽  
Rachid Nasri
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Thickness Distribution ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Fe Model ◽  
Forming Process ◽  
Shape Accuracy ◽  
Truncated Cone

Incremental forming is a recent forming process that allows a sheet to be locally deformed with a hemispherical tool in order to gradually shape it. Despite good lubrication between the sheet and the tip of the smooth hemisphere tool, ductility often occurs, limiting the formability of titanium alloys due to the geometrical inaccuracy of the parts and the inability to form parts with a large depth and wall angle. Several technical solutions are proposed in the literature to increase the working temperature, allowing improvement in the titanium alloys’ formability and reducing the sheet thinning, plastic instability, and failure localization. An experimental procedure and numerical simulation were performed in this study to improve the warm single-point incremental sheet forming of a deep truncated cone in Ti-6Al-4V titanium alloy based on the use of heating cartridges. The effect of the depth part (two experiments with a truncated cone having a depth of 40 and 60 mm) at hot temperature (440 °C) on the thickness distribution and sheet shape accuracy are performed. Results show that the formability is significantly improved with the heating to produce a deep part. Small errors are observed between experimental and theoretical profiles. Moreover, errors between experimental and numerical displacements are less than 6%, which shows that the Finite Element (FE) model gives accurate predictions for titanium alloy deep truncated cones.

Springback Analysis of TC4 Titanium Alloy Complex Part with Double Curvature under Single Point Incremental Forming Process

2012 ◽  
Vol 468-471 ◽  
pp. 1094-1098
Author(s):  
Fen Qiang Li ◽  
Jian Hua Mo
Keyword(s):  
Titanium Alloy ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Complex Structure ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Cold Forming ◽  
Tc4 Titanium Alloy ◽  
Double Curvature

To make the structure of aircraft meet the aerodynamic requirements, complex lightweight structures such as double curvature shape and high-strength lightweight materials such as titanium alloy are generally used in design and forming of aircraft skin parts. But the forming processes and problems aimed to this kind of parts remain to be investigated further now. In this paper, based on single point incremental forming process, the TC4 titanium alloy aircraft parts with a complex double curvature was studied. In order to reduce the springback during the forming process an appropriate addendum surface was added to the part surface, and then ABAQUS software was applied to carry out numerical simulation of the forming and springback process. The results show that springback of complex titanium part with double curvature is small at both ends of part while large in the middle and the distribution of springback orientation depends on the curvature. For that the part is difficult to form by single point incremental forming process without springback compensation, so the tool path needs to be improved firstly. The simulation results can play a role for guiding the parameters selection and the compensated surface design of single point incremental forming process which can achieve the cold forming of parts with complex structure for poor formability materials.

On the high-speed Single Point Incremental Forming of titanium alloys

CIRP Annals ◽  
2013 ◽  
Vol 62 (1) ◽  
pp. 243-246 ◽  
Author(s):  
G. Ambrogio ◽  
F. Gagliardi ◽  
S. Bruschi ◽  
L. Filice
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming

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.

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.

Study on Forming Behaviour of Friction Stir Welded Blanks During Single Point Incremental Forming (SPIF) Process

2020 ◽  
Author(s):  
Shalin Marathe ◽  
Harit Raval
Keyword(s):  
Friction Stir Welding ◽  
Incremental Forming ◽  
Single Point ◽  
Base Material ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process ◽  
Friction Stir ◽  
Welding Processes

Abstract The automobile, transportation and shipbuilding industries are aiming at fuel efficient products. In order to enhance the fuel efficiency, the overall weight of the product should be brought down. This requirement has increased the use of material like aluminium and its alloys. But, it is difficult to weld aluminium using conventional welding processes. This problem can be solved by inventions like friction stir welding (FSW) process. During fabrication of product, FSW joints are subjected to many different processes and forming is one of them. During conventional forming, the formability of the welded blanks is found to be lower than the formability of the parent blank involved in it. One of the major reasons for reduction in formability is the global deformation provided on the blank during forming process. In order to improve the formability of homogeneous blanks, Single Point Incremental Forming (SPIF) is found to be giving excellent results. So, in this work formability of the welded blanks is investigated during the SPIF process. Friction Stir Welding is used to fabricate the welded blanks using AA 6061 T6 as base material. Welded blanks are formed in to truncated cone through SPIF process. CNC milling machine is used as SPIF machine tool to perform the experimental work. In order to avoid direct contact between weld seam and forming tool, a dummy sheet was used between them. As responses forming limit curve (FLC), surface roughness, and thinning are investigated. It was found that use of dummy sheet leads to improve the surface finish of the formed blank. The formability of the blank was found less in comparison to the parent metal involved in it. Uneven distribution of mechanical properties in the welded blanks leads to decrease the formability of the welded blanks.

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