scholarly journals Evaluation of the Formability and Dimensional Accuracy Improvement of Ti6Al4V in Warm SPIF Processes

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 272 ◽  
Author(s):  
Jesús Naranjo ◽  
Valentín Miguel ◽  
Alberto Martínez ◽  
Juana Coello ◽  
María Manjabacas
Keyword(s):  
High Performance ◽  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Design Stage ◽  
Forming Process ◽  
Accuracy Improvement ◽  
Dimensional Precision ◽  
Heating Device ◽  
Surface Finishes

Single Point Incremental Forming (SPIF) has great potential as it can be easily implemented and the forming process does not require the use of dies. However, its application to high performance alloys such as Ti6Al4V has not been resolved due to its characteristic low formability. In the literature, studies on the warm SPIF process applied to this alloy report improved formability. However, in some of these studies the procedures used are complex and in others the surface finishes obtained are unsatisfactory. The present study proposes a methodology consisting of a simple heating device which permits working at moderate temperatures and quantifies the benefit of the temperature on the alloy formability, the forces acting during the process, and finally the dimensional precision of the parts produced. Working temperatures in the range of 300–400 °C significantly reduce forces, increase formability of the alloy, and substantially reduce springback. However, the springback values suggest the need for dimensional compensation at the design stage of products.

scholarly journals Simulation of incremental forming processes of a pyramidal ring made of two materials

2018 ◽  
Vol 19 (3) ◽  
pp. 313
Author(s):  
Masood Ghassabi ◽  
Milad Salimi ◽  
Mohammad Haghpanahi
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Cnc Machine ◽  
Forming Force ◽  
Forming Process ◽  
Dimensional Precision

Incremental forming is one of the most well-known forming processes for complex and asymmetric parts. This method uses a CNC machine, simple forming tool, and a die. This study focused on effects of some parameters such as the material, feed rate, pitch, rotational speed and movement strategy of tool on the dimensional precision, forming force, thickness distribution and fracture in the welding area. The results showed that single point incremental forming (SPIF) led to a better thickness distribution with lower tool force, whereas two-point incremental forming led to better dimensional accuracy. Rotational speed does not have any significant impact on the forming process while decreasing the feed rate partially reduced the forming force. According to the results, although dimensional precision in double point incremental forming is better than SPIF, when it comes to the thickness distribution, forming force, and economic issues, SPIF is in favor. The results also showed that by connecting two materials, different parameters for the two materials could be investigated simultaneously in one simulation process.

Formability of aluminum 5083 friction stir welded blank in two-point incremental forming process

2017 ◽  
Vol 232 (3) ◽  
pp. 267-280 ◽  
Author(s):  
Pejman Ebrahimzadeh ◽  
Hamid Baseri ◽  
Mohammad J Mirnia
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Welding Parameters ◽  
Forming Process ◽  
Minimum Thickness ◽  
Friction Stir ◽  
Series Of Experiments ◽  
Rotary Speed ◽  
Aluminum 5083

In the present study, an attempt was made to analyze the formability of aluminum 5083 fiction stir welded blank through an incremental forming process. Experiments are performed on the joints which were fabricated by optimal welding parameters with 73% strength sufficiency. Firstly, a series of experiments were carried out to compare the formability of welded blank in single-point and two-point incremental forming operations, under different wall angles. Thereafter, an experimental study based on response surface methodology was carried out to find out the effect of incremental forming factors on the dimensional accuracy and minimum thickness. It was found from the results that irrespective of the wall angle, the formability of welded blank (i.e. forming height until occurrence of tear) which formed in two-point incremental forming process is relatively higher than that of single-point incremental forming. Also, statistical analysis revealed that tool rotary speed and step down has a significant effect on the critical thickness, while springback is affected by the sequence of tool rotary speed and feed rate.

scholarly journals Achieving Accuracy Improvements for Single-Point Incremental Forming Process Using a Circumferential Hammering Tool

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 482
Author(s):  
Daniel Nasulea ◽  
Gheorghe Oancea
Keyword(s):  
Mathematical Models ◽  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Machining Accuracy ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Area ◽  
Forming Tools ◽  
Full Factorial

The paper presents a novel solution for improving the accuracy of the wall area of parts manufactured by single point incremental forming. Thus, a forming tool with a special design that works according to the principle of circumferential hammering is deployed, with a direct improving effect of the forming conditions and consequently of the dimensional accuracy of the part. The research is focused on an experimental study of frustum-of-cone shapes manufactured from sheet metal blanks of DC05 deep drawing steel of 1 mm thickness. A typical customary technological setup is used for the single point incremental forming process, without any additional elements, and two forming tools, a hemispherical and a special one, which use the circumferential hammering effect. Several preliminary tests using both tools were performed in order to prove that part accuracy can be significantly improved by using the circumferential hammering tool. The research was further expanded to investigate the influence on part wall dimensional accuracy of three factors: tool spindle speed, tool feed rate and part dimensional configuration. Using a full factorial plan of experiments the results of 32 test runs were processed. All parts were machined adequately, free of any material fracturing. Based on the achieved machining accuracy of the part walls, precision mathematical models were developed for the prediction of part dimensional accuracy in those areas. The mathematical models were validated by practice, as the predicted accuracies were matched by the experimental results.

scholarly journals Experimental Study the Effect of Tool Geometry on Dimensional Accuracy in Single Point Incremental Forming (SPIF) Process

2018 ◽  
Vol 21 (1) ◽  
pp. 108 ◽  
Author(s):  
Aqeel Sabree Bedan ◽  
Halah Ali Habeeb
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Tool Geometry ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Angle ◽  
Product Profile ◽  
Tool Diameter

Incremental forming is a flexible sheet metal forming process which performed by utilizes simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. One limitations of single point incremental forming (SPIF) process is the error occur between the CAD design and the product profile. This work presents the single point incremental forming process for produced pyramid geometry and studied the effect of tool geometry, tool diameter, wall angle, and spindle speed on the dimensional accuracy. Three geometries of forming tools were used in experimental work: ball end tool, hemispherical tool, and flat with round corner tool. The sheet material used was pure Aluminum (Al 1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The products dimensions were measured by utilized the dimensional sensor measuring instrument. The extracted results from the single point incremental forming process indicated the best acceptance between the CAD profile and product profile was found with the ball end tool and diameter of (10 mm), wall angle (50°) and the rotational speed of the tool was (800 rpm).

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

Effect of process parameters on formability in two-point incremental forming-machining of planar and twisted AA5083 blades

2022 ◽  
pp. 095440542110697
Author(s):  
Hossein Ghorbani-Menghari ◽  
Mehrdad Azadipour ◽  
Mehran Ghasempour-Mouziraji ◽  
Young Hoon Moon ◽  
Ji Hoon Kim
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Machining Process ◽  
Curved Surface ◽  
Forming Process ◽  
Forming Temperature ◽  
Feature Based ◽  
Tool Diameter

The deformation machining process (DMP) involves machining and incremental forming of thin structures. It can be applied for manufacturing products such as curved-surface blades without using 5-axis computerised numerical control machines. This work presents the effect of tool diameter and forming temperature on spring-back and dimensional accuracy of a simple fabricated part. The results of the first phase of the study are utilised to design the fabrication process of a curved surface blade. A feature-based algorithm is used to design the tool path for the forming process. The dimensional accuracy of the final product is improved through warm forming, two-point incremental forming, and extension of the bending zone to the outside of the product edges. The results show that DMP can be used to fabricate complex curved-surface workpieces with acceptable dimensional accuracy.

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.

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