scholarly journals On the Influence of the Tool Path and Intrusion Depth on the Geometrical Accuracy in Incremental Sheet Forming

Metals ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 661
Author(s):  
Roman Ulrich Christopher Schmitz ◽  
Thomas Bremen ◽  
David Benjamin Bailly ◽  
Gerhard Kurt Peter Hirt
Keyword(s):  
Sheet Metal ◽  
Tool Path ◽  
Sheet Material ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Forming Process ◽  
Geometrical Accuracy ◽  
Metal Forming Process ◽  
Short Time ◽  
Intrusion Depth

Incremental sheet forming (ISF) is a flexible sheet metal forming process to realize products within short time from design to the first produced part. Although fundamental research on ISF has been carried out around the world, ISF still misses commonly required tolerances for industrial application. In this study, the influences of tool path as well as intrusion depth of the forming tool into the sheet material on the geometrical accuracy were investigated. In the conducted experiments, both flat and stretch-formed sheet metal blanks with different tool paths and intrusion depths were examined. Experimental and numerical investigations showed that changes in the range of a tenth millimeter of the intrusion depth with a consistent tool path lead to different resulting part geometries. A better understanding of the sensitive influence of the tool path and the intrusion depth on the resulting geometry might lead to more accurate parts in the future.

Comparison of some Final Part Geometrical Characteristics of Cylindrical Cups Manufactured by Deep-Drawing and Two-Point Incremental Sheet Forming

2009 ◽  
Vol 410-411 ◽  
pp. 355-363 ◽  
Author(s):  
Babak Taleb Araghi ◽  
Markus Bambach ◽  
Gerhard Hirt
Keyword(s):  
Sheet Metal ◽  
Deep Drawing ◽  
Thickness Distribution ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Surface Strain ◽  
Forming Process ◽  
Sheet Metal Parts ◽  
Part Surface ◽  
Metal Forming Process

Asymmetric incremental sheet forming (AISF) is a new sheet metal forming process in which sheet metal parts are produced by CNC-controlled movements of a simple ball-headed forming tool. Despite its flexibility and successful application in many cases, AISF has not yet been established in an industrial context due to some still existing process limits such as severe thinning, which strongly depends on the inclination of the part surface, as well as a limited geometric accuracy due to springback. Furthermore, there is little knowledge available about the properties of parts produced by AISF, especially in comparison to deep-drawn parts. The aim of the present paper is to compare cylindrical cups manufactured by deep-drawing and AISF regarding the resulting strain and thickness distribution. For AISF, different forming strategies were applied. Comparisons of the wall thickness and surface strain distributions show similar results for the cup produced by deep-drawing and the best cup produced by AISF, but the surface strains and the sheet thinning in the parts formed by AISF were larger than in the deep-drawn part.

Development of Tool Path Correction Algorithm in Incremental Sheet Forming

2014 ◽  
Vol 622-623 ◽  
pp. 382-389 ◽  
Author(s):  
Antonio Fiorentino ◽  
G.C. Feriti ◽  
Elisabetta Ceretti ◽  
C . Giardini ◽  
C.M.G. Bort ◽  
...  
Keyword(s):  
Tool Path ◽  
Error Distribution ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Correction Algorithm ◽  
Forming Process ◽  
Part Geometry ◽  
Toolpath Planning ◽  
The Difference ◽  
Tool Path Correction

The problem of obtaining sound parts by Incremental Sheet Forming is still a relevant issue, despite the numerous efforts spent in improving the toolpath planning of the deforming punch in order to compensate for the dimensional and geometrical part errors related to springback and punch movement. Usually, the toolpath generation strategy takes into account the variation of the toolpath itself for obtaining the desired final part with reduced geometrical errors. In the present paper, a correction algorithm is used to iteratively correct the part geometry on the basis of the measured parts and on the calculation of the error defined as the difference between the actual and the nominal part geometries. In practice, the part geometry is used to generate a first trial toolpath, and the form error distribution of the resulting part is used for modifying the nominal part geometry and, then, generating a new, improved toolpath. This procedure gets iterated until the error distribution becomes less than a specified value, corresponding to the desired part tolerance. The correction algorithm was implemented in software and used with the results of FEM simulations. In particular, with few iterations it was possible to reduce the geometrical error to less than 0.4 mm in the Incremental Sheet Forming process of an Al asymmetric part, with a resulting accuracy good enough for both prototyping and production processes.

Incremental Sheet Forming with an Industrial Robot – Forming Limits and Their Effect on Component Design

2005 ◽  
Vol 6-8 ◽  
pp. 457-464 ◽  
Author(s):  
L. Lamminen
Keyword(s):  
Sheet Metal ◽  
Industrial Robot ◽  
Forming Limit Diagram ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Point Of View ◽  
Forming Limit ◽  
Forming Process ◽  
3D Cad ◽  
Component Design

Incremental sheet forming (ISF) has been a subject of research for many research groups before. However, all of the published results so far have been related to either commercial ISF machines or ISF forming with NC mills or similar. The research reported in this paper concentrates on incremental sheet forming with an industrial robot. The test equipment is based on a strong arm robot and a moving forming table, where a sheet metal blank is attached. The tool slides on the surface of the sheet and forms it incrementally to the desired shape. The robot is capable of 5-axis forming, which enables forming of inwards curved forms. In this paper the forming limit diagram (FLD) for ISF with the robot is presented and it is compared with conventional forming limit diagrams. It will be shown that the conventional FLD does not apply to incremental forming process. Geometrical accuracy of sample pieces is also studied. Cones of different shapes are formed with the robot equipment and their correspondence with the 3D CAD model is evaluated. The results are compared with other results of accuracy of incremental sheet forming, reported earlier by other researchers. The third issue covered in this article is a product development point of view to incremental sheet forming. In addition to fast prototyping and low volume production of sheet metal parts, ISF brings new possibilities to sheet metal component design and manufacturing. These possibilities can only be exploited if design rules, that will take the possibilities and limitations of the method into account are created for ISF.

Comparison between SPIF with Robot and CNC Machine

2011 ◽  
Vol 473 ◽  
pp. 929-936 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Claudio Giardini ◽  
Silvio Antonioni
Keyword(s):  
Degrees Of Freedom ◽  
Tool Path ◽  
Sheet Material ◽  
Sheet Thickness ◽  
Cnc Machine ◽  
Forming Process ◽  
Advantages And Disadvantages ◽  
Shape Errors ◽  
Metal Forming Process ◽  
Sheet Formability

This paper deals with Incremental Sheet Forming (ISF) a sheet metal forming process that knew a wide development in the last years. A lot of experimental and simulative researches have been conducted in this field with different aims: to study the sheet formability and part feasibility; to define models able to forecast the final sheet thickness; to understand how the sheet deforms and how formability limits can be defined. Another very important issue is related with the tool path optimization. In fact, the process is characterized by high springback which causes dimensional defects. When IF is performed by a robot, the capabilities of the technology is improved in terms of obtainable shapes (it is possible to use the 6 degrees of freedom of the robot), but the shape errors seem to be higher due to the lower robot stiffness in comparison with CNC machine. In this work the comparison between two different ISF configurations, tool mounted on a CNC machine or tool mounted on a robot, is reported. A suitable geometry was investigated working different sheet material types and sheet thicknesses. The results in terms of geometrical accuracy and sheet deformation have been analyzed in order to define advantages and disadvantages of these two techniques. An analysis on the process forces has been carried out too.

scholarly journals The Effect of Forming Parameters on the Sheet Stretch in Incremental Sheet Forming (ISF) Process on CNC Lathe Machine

2013 ◽  
Vol 634-638 ◽  
pp. 2894-2898 ◽  
Author(s):  
M Moayedfar ◽  
Zulkiflle Leman ◽  
H Mirabi ◽  
B.T.H.T. Baharuddin
Keyword(s):  
Sheet Metal ◽  
Feed Rate ◽  
Tool Material ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Spindle Speed ◽  
Forming Process ◽  
Forming Parameters ◽  
Cnc Lathe ◽  
Lathe Machine

The effect of forming parameters during the incremental sheet forming process (ISF) was studied for a circular shape sheet part. ISF is known as a rapid prototyping method to pro-duce sheet metal parts in a batch production series. ISF has found to be useful and advantageous which increases its application in industry. A CNC lathe machine was used in this study because it was easily programmed to move an indenter which worked as the tool, through the sheet metal which was clamped on a plain rounded mold. The work also investigated the influence of some process variables such as spindle speed, tool material; tool feed rate and temperature during the forming procedure. The results showed that a proper spindle speed and tool feed rate at some stage in the forming process improved the surface quality and the rate of penetration.

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