scholarly journals Influence of Forming Parameters on the Mechanical Behavior of a Thin Aluminum Sheet Processed through Single Point Incremental Forming

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1461
Author(s):  
Muhammad Ilyas ◽  
Ghulam Hussain ◽  
Haris Rashid ◽  
Mohammed Alkahtani
Keyword(s):  
Mechanical Properties ◽  
Yield Strength ◽  
Residual Stresses ◽  
Strain Hardening ◽  
Incremental Forming ◽  
Single Point ◽  
Strain Hardening Exponent ◽  
Single Point Incremental Forming ◽  
Forming Parameters ◽  
Tool Diameter

Incremental sheet forming (ISF) is an economical process for batch production. This paper investigates post-forming mechanical properties with an emphasis on the relationship between residual stresses, strengths, micro-hardness and the strain-hardening exponent. Moreover, the influence of important process parameters on the post-forming tensile properties and hardness is analyzed. A Taguchi statistical analysis method is applied to study the effect of forming parameters and identify the best combinations to enhance the mechanical properties of the commercial aluminum. The results reveal that direct relationships exist for the plots of: (i) the strain-hardening exponent vs. the post-necking strain and (ii) difference of post-forming strengths vs. the strain-hardening exponent. Furthermore, the post-forming yield strength can be enhanced by 66.9% through the Single Point Incremental Forming (SPIF). Similarly, the ductility can be doubled by conducting the SPIF after performing the annealing of the as-received rolled sheet. In the present study, parts formed at a wall angle (θ) of 40° with a tool diameter (d) of 6 mm exhibit the highest strength. Moreover, most ductile parts will be obtained at ω = 1500 rpm, d = 22 mm and θ = 20°. It has also been shown that the compressive residual stresses are favorable for higher yield strength and improve hardness of the formed parts.

scholarly journals Interaction of Process Parameters, Forming Mechanisms, and Residual Stresses in Single Point Incremental Forming

Metals ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 656 ◽  
Author(s):  
Fabian Maaß ◽  
Marlon Hahn ◽  
A. Erman Tekkaya
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Stress State ◽  
Residual Stresses ◽  
Process Parameters ◽  
Process Model ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Residual Stress State

The residual stress state of a sheet metal component manufactured by metal forming has a significant influence on the mechanical properties, and thus determines the time until the component fails, especially for dynamic loads. The origin of the resulting residual stress state of incrementally formed parts with regard to the forming mechanisms of shearing, bending, and the normal stress component is still under investigation. The relationship between the process parameters, the forming mechanisms, and the resulting residual stress state for a complex part geometry manufactured by single point incremental forming (SPIF) is presented in this publication. For this purpose, a validated numerical process model is used to analyze the influence of the step-down increment Δz for truncated cones on the characteristics of the forming mechanisms and the resulting residual stress state. For the first time the forming mechanisms are evaluated numerically on both sides of the formed component. A relationship between the process parameters, forming mechanisms, residual stresses, and the mechanical properties of an incrementally formed component is shown. Shearing-induced hardening is identified as a relevant influence on the residual stress state of cones.

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.

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).  

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

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 ANALYSIS OF THE SURFACE QUALITY OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING

2016 ◽  
Vol 19 (3) ◽  
Author(s):  
CRINA RADU ◽  
EUGEN HERGHELEGIU ◽  
ION CRISTEA ◽  
CAROL SCHNAKOVSZKY
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Metal Sheets ◽  
Vertical Step ◽  
Tool Diameter ◽  
Aluminium Metal

<p>The aim of the current work was to analyse the influence of the process parameters (tool diameter, size of the vertical step of tool, feed rate and spindle speed) on the quality of the processed surface, expressed in terms of roughness and macrostructure in the case of parts processed by single point incremental forming. The analysis was made on A1050 aluminium metal sheets. The obtained results revealed that the process parameters influence differently the surface quality, the worst influence being exerted by the increase of the vertical step of tool. </p>

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.

STUDY ON THE INFLUENCE LAWS OF MECHANICAL PROPERTIES ON STIFFNESS OF AUTOMOTIVE BODY PANELS

2009 ◽  
Vol 23 (06n07) ◽  
pp. 1634-1639 ◽  
Author(s):  
LIHONG ZHAO ◽  
SHUYONG JIANG ◽  
ZHENG YI REN ◽  
HAIPING YU ◽  
YUYING YANG
Keyword(s):  
Mechanical Properties ◽  
Yield Strength ◽  
Strain Hardening ◽  
Shallow Shell ◽  
Anisotropy Parameter ◽  
Weight Coefficient ◽  
Great Accuracy ◽  
Strain Hardening Exponent ◽  
Forming Process ◽  
Auto Body

The criterion and research technique of auto body panels stiffness are introduced in this work, and the finite element models (FEM) of cylindrical shallow shell that could represent auto body panels are established. Simulations of forming, springback and stiffness on cylindrical shallow shell are carried out. The simulations show great accuracy with the experimental results. Extensive simulated results of the influence laws of material mechanical properties on stiffness are achieved, such as yield strength, strain-hardening exponent, Young's modulus, anisotropy parameter and strength coefficient. With comparison of the weight coefficient of material mechanical properties on stiffness, it can be concluded that the Yong's modulus, strain-hardening exponent and yield strength are key influencing factors of stiffness. With the analysis of distribution of the strain after cylindrical shallow shell forming, plastic deformation during the forming process resulting in work-hardening of the material is one of the main reasons for increasing stiffness.

scholarly journals Study the Effect of Multilayer Single Point Incremental Forming on Residual Stresses for Bottom Plates

2017 ◽  
Vol 13 (3) ◽  
pp. 99-107
Author(s):  
Aseel Hamad Abed ◽  
Aqeel Sabree Bedan ◽  
Mohanad Faeq Noori
Keyword(s):  
Residual Stresses ◽  
Incremental Forming ◽  
Single Point ◽  
Important Task ◽  
Bottom Plate ◽  
Single Point Incremental Forming ◽  
Production Operation ◽  
Single Plate ◽  
And Control

Abstract   Knowing the amount of residual stresses and find technological solutions to minimize and control them during the production operation are an important task because great levels of deformation which occurs in single point incremental forming (SPIF), this induce highly non-uniform residual stresses. In this papera propose of a method for multilayer single point incremental forming with change in thickness of the top plate (0.5, 0.7, 0.9) mm and lubrication or material between two plates(polymer, grease, grease with graphite, mos2) to knowing an effect of this method  and parameters on residual stresses for the bottom plates. Also compare these results for the bottom plates with the single plate at same thickness 0.9 mm.The results showed that when increase thickness of the top plate the value of residual stresses will decrease for bottom plates and when used graphite with grease between two plates gives less residual stresses (R.S = 60.173 MPa.) reverse when used Mos2 which will gives a larger residual stresses (R.S = 146.617 MPa.) in the bottom plate. Keywords: Multilayer Single Point Incremental Forming (SPIF), Residual Stresses, Lubrication.

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