Determination of Technological Forces in the Incremental Forming Process

2013 ◽  
Vol 371 ◽  
pp. 133-137
Author(s):  
Radu Eugen Breaz ◽  
Melania Tera ◽  
Octavian Bologa ◽  
Sever Gabriel Racz
Keyword(s):  
Image Processing ◽  
Theoretical Model ◽  
Data Acquisition ◽  
Incremental Forming ◽  
Single Point ◽  
Cnc Milling ◽  
Forming Process ◽  
Feed Drive ◽  
Cnc Milling Machine

The paper presents a joint theoretical and experimental approach to determine the technological forces within the asymmetric single point incremental forming ASPIF process, based upon a theoretical model, image processing and data acquisition. The first step of this approach was to develop a theoretical model of the forces within the process, based upon the model of a mechanical feed drive of a CNC milling machine. By means of this model, relationships between the resistant torque at the motor spindle level and the technological force on the movement axis could be determined. Using an image processing method, which allowed the user to extract information within the machines operator panel and analytical relationships, the technological forces were determined. The results were compared with the measured values, obtained by means of a data acquisition system.

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.

Experimental Study on a New Method of Double Side Incremental Forming

2008 ◽  
Author(s):  
Yongjun Wang ◽  
Ying Huang ◽  
Jian Cao ◽  
N. Venkata Reddy
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Cnc Milling ◽  
Analysis Model ◽  
Surface Machining ◽  
Cnc Milling Machine ◽  
Geometrical Features ◽  
New Process ◽  
Sheet Metal Incremental Forming

This paper presents a new configuration for sheet metal incremental forming using DSIF (Double Sided Incremental Forming) to overcome the limitation of single point incremental forming (SPIF). The new process can produce geometrical features on either side of the initial plane of the sheet without changing setup. A component having such challenging features is selected to demonstrate the capabilities of the proposed method and a contour tool path is generated using UniGraphics (UG) surface machining module and formed by mounting the new setup on a CNC milling machine. The final formed shape was scanned and compared to the designed profile. In addition, two more components having cylindrical and spherical geometries are formed to study the effect of geometry on the accuracy of the component that can be produced by using the proposed method. A simple analysis model has been developed to explain the effect of squeezing and stretching to the part elongation during the DSIF process.

Investigations about the Single Point Incremental Forming of Anisotropic Titanium Alloy Sheets

2011 ◽  
Vol 264-265 ◽  
pp. 188-193 ◽  
Author(s):  
G. Palumbo ◽  
Marco Brandizzi ◽  
G. Cervelli ◽  
M. Fracchiolla
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Tensile Tests ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process ◽  
Fe Simulations ◽  
Shape Errors ◽  
Optical Strain

The present work focuses the attention on the Single Point Incremental Forming (SPIF) of the Titanium (Ti) alloy Ti-6Al-4V. Tensile tests were carried out using the optical strain measurement system Aramis3D, in order to determine the mechanical behaviour of the alloy and to investigate the anisotropy of such alloy. Finite Element (FE) simulations of the SPIF process (using ABAQUS/explicit) were performed using a simple but non-axialsymmetric shape (truncated pyramid) with the aim of investigating the effect of both the tool/pitch ratio (D/p) and the draw angle (α), taking into account the anisotropic behaviour. The analysis of plastic strains and thinning maps, together with the evaluation of shape errors originated by the forming process, highlighted that the parameter D/p plays a key role in the SPIF. Results from the preliminary FE analysis were used for investigating the production by SPIF of an automotive component (car door shell). A specific subroutine was created by the authors for automatically generating the tool path to be used in both the FE simulations and the manufacturing of parts by SPIF on a CNC milling machine.

scholarly journals Simulation of the Single Point Incremental Forming of Polyamide and Polyethylene Sheets

2019 ◽  
Vol 290 ◽  
pp. 03014
Author(s):  
Nicolae Alexandru Roşca ◽  
Mihaela Oleksik
Keyword(s):  
Incremental Forming ◽  
True Strain ◽  
Single Point ◽  
Polymeric Materials ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Explicit Analysis ◽  
Polyamide 6.6 ◽  
Experimental Researches

The present paper aims the theoretical study, using the finite element method, on the single point incremental forming process of two polymeric materials: polyamide 6.6 and high-density polyethylene. The experimental researches used for the determination of the true stress - true strain curves for two materials are presented, which are necessary for their introduction into the simulation. The explicit analysis is carried out with the Ls-Dyna program and the results of the analysis were focused on the major strain, minor strain, thickness reduction, forces on the process and total energy consumed in the process.

Effect of Toolpath on the Springback of 2024-T3 Aluminum During Single Point Incremental Forming

2015 ◽  
Author(s):  
Zachary C. Reese ◽  
Brandt J. Ruszkiewicz ◽  
Chetan P. Nikhare ◽  
John T. Roth
Keyword(s):  
Residual Stresses ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Final Part ◽  
Cnc Milling ◽  
Forming Process ◽  
Step Size ◽  
Part Geometry

Incremental forming is a nontraditional forming method in which a spherical tool is used to asymmetrically deform sheet metal without the need for expensive allocated dies. Incremental forming employs a tool path similar to that used when CNC milling. Hence, when forming a part, the forming tool makes a series of passes circumferentially around the workpiece, gradually spirally stepping down in the z-axis on each sequential pass. This tool path deforms the sheet metal stock into the final, desired shape. These passes can start from the outer radius of the part and work in (Out to In, OI forming) or they can start from the center of the shape and work outward (In to Out, IO forming). As with many sheet metal operations, springback is a big concern during the incremental forming process. During the deformation process, residual stresses are created within the workpiece causing the final formed shape to springback when it is unclamped, sometimes very significantly. The more complex the geometry of the final part and the more total deformation that occurs when forming the geometry, the greater the residual stresses that are generated within the part. The residual stresses that have built up in the piece cause more significant distortion to the part when it is released from the retaining fixturing. This paper examines how the step size (in the z direction), OI vs. IO forming, and final part geometry affect the total springback in a finished piece. For all of these tests 0.5 mm thick sheets of 2024-T3 aluminum were used to form both the truncated pyramid and truncated cone shape. From this investigation it was found that smaller step sizes result in greater springback, IO is significantly less effective in forming the part (due to workpiece tearing), and final part geometry plays an important role due to the creation of residual stresses that exist in corners.

Comparative Study for Springback Prediction on Single Point Incremental Forming Process

2014 ◽  
Vol 622-623 ◽  
pp. 375-381
Author(s):  
Valentin Oleksik ◽  
Adrian Pascu ◽  
Ioan Bondrea ◽  
Eugen Avrigean ◽  
Liviu Rosca
Keyword(s):  
Comparative Study ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Machined Surface ◽  
Fully Integrated ◽  
Explicit Dynamic ◽  
Springback Prediction

The present paper proposes a comparative study in order to determine the springback in single point incremental forming process. Using the Ls-Dyna software the process was simulated for one piece in frustum of pyramid shape. In the end of the explicit dynamic analysis, it was run, using the same software, an implicit analysis to determine the springback. For this comparison study we selected four different shell formulations. The results obtained in this simulation were compared with those obtained experimentally for the same part. The experimental research was conducted on a robot and, on the opposite side of the machined surface, an Aramis measuring optical system was placed to allow the online determination of deformations, displacements and thinning of material. Also, using this system, the springback was determined at the end of forming process. The closest values were obtained when using fully integrated formulation with thickness-stretch with 11 integration points on material thickness.

CAD/CAM Strategies for a Parallel Kinematics SPIF Machine

2013 ◽  
Vol 554-557 ◽  
pp. 2221-2229 ◽  
Author(s):  
João B.S. Farias ◽  
Miguel A.B.E. Martins ◽  
Daniel G. Afonso ◽  
Sonia R.H. Marabuto ◽  
Jorge A. Ferreira ◽  
...  
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Parallel Kinematics ◽  
Forming Process ◽  
Advantages And Disadvantages ◽  
Cad Cam ◽  
Five Axis

Single point incremental forming has attracted the interest of researchers in the last decade for the production of prototypes and small batch production of sheet-based parts [1, 2]. This technique allows the manufacture of parts without using expensive die sets. The SPIF (Single point incremental forming) process can be performed on different equipments such as adapted CNC milling machines, serial robots and built proposed machines [3]. Every solution has advantages and disadvantages. This work presents the CAD/CAM strategies for a parallel kinematics SPIF machine, designed and built at the University of Aveiro [3]. This machine brings a new approach to the SPIF industry. The machinery used to perform SPIF operations has limitations in their work volume with limited movements and in the magnitude of applicable forces. With that in mind, this machine was projected to overcome that obstacle, and was provided with a system with 6 degrees of freedom, while maintaining the ability to apply high loads. The disadvantage is the increase in volume occupied by the kinematic system. The manufacture of new parts could be reached out with more flexibility on the chosen tool path. The first step is the product design in the commercial CAD system. Next step is generating the tool path of the forming tool. This step is very important to achieve the desired part shape. It is used a commercial CAM system (EdgeCAM 2012®), which has resources from three up to five axis strategies. The last step is to send the information to the machine’s control system, based on real-time software. This paper will describe each step with more details.

scholarly journals A CALCULATION OF POWER FOR FORMING METAL SHEET BY SPIF PROCESS

2009 ◽  
Vol 12 (4) ◽  
pp. 5-17
Author(s):  
Nam Thanh Nguyen ◽  
Dien Khanh Le ◽  
Sy Van Le
Keyword(s):  
Crystal Plasticity ◽  
Manufacturing Process ◽  
Incremental Forming ◽  
Single Point ◽  
Metal Sheet ◽  
Single Point Incremental Forming ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Cad Cam

This paper attempts to represent a case of calculating of the energy power that is consumed by CNC milling machine when manufacturing via forming membrane metal sheet by SPIF (Single Point Incremental Forming), the recent manufacturing process of metal sheet forming by drafting a no cutting-edge spheric tip tool on a clamped metal sheet. The calculation is based on the disclocation, the crystal plasticity and the slip of lattices inside the structure of the deformed metal. In the while time there is a series of empirical species of 24 groups batch of workpieces that were also machined by CNC milling machine Bridge Port VMC500, CAD/CAM Lab., FME of HCMUT for checking this calculation on consumed power.

Implementing Thermomechanical Properties of 22MnB5 Steel during Hot Single-Point Incremental Forming

2017 ◽  
Vol 890 ◽  
pp. 362-366 ◽  
Author(s):  
Amar Al-Obaidi ◽  
Verena Kräusel ◽  
Dirk Landgrebe
Keyword(s):  
Mechanical Properties ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Thermomechanical Properties ◽  
Alloy Sheet ◽  
Process Time ◽  
Single Point Incremental Forming ◽  
Cnc Milling ◽  
Forming Process

The strategy in manufacturing hardened parts used in car bodies is to tailor the mechanical properties. This is done by combining together a high-strength region and a high-toughness region to ensure the crash performance required. Other successive secondary operations such as trimming, joining and welding can be improved as a result of the tailoring process. In this work, the mechanical properties of 22MnB5 alloy sheet material produced by single-point incremental forming have been tailored. For this purpose, the sheets were locally heated by induction during the forming process and subsequently cooled. The sheet temperature was controlled by the CNC milling machine feed rate and induction power. As a result, the produced tailored parts consist of three different regions: ductile, transition and hardened regions. The Vickers hardness values were 583 HV1 and 175 HV1 for the hardened and ductile regions, respectively. The proposed application allows forming and quenching at the same time without transfer and to reduce the process time.

Sign in / Sign up

Export Citation Format

Share Document