FEM Analysis of Sheet Incremental Forming Process

2014 ◽  
Vol 571-572 ◽  
pp. 1079-1082
Author(s):  
Jie Liu
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Metal Layer ◽  
Three Dimensional ◽  
Rapid Prototype ◽  
Fem Analysis ◽  
Layer By Layer ◽  
Forming Process ◽  
Rapid Prototype Technology ◽  
Forming Technology

Sheet incremental forming is a new sheet metal dieless forming technology. This paper introduced the fundamentals of the sheet incremental forming process. Based on the principle of “layered manufacture” in rapid prototype technology, this process resolves the intricate three-dimensional geometry information of the workpiece into a series of two-dimensional data, which can be used by an NC system to control a forming tool to make a curvilinear movement over the raw sheet metal layer by layer until the component wanted is formed. This paper introduced the sheet incremental forming system and metal digital forming technology. An FEM model of the incremental forming process is established, and a typical process is analyzed to instruct the parameters selection and the optimization of the forming tracks.

A New Incremental Sheet Forming Process Based on Layer Manufacture

2014 ◽  
Vol 607 ◽  
pp. 124-127
Author(s):  
Jie Liu
Keyword(s):  
Sheet Metal ◽  
Metal Layer ◽  
Three Dimensional ◽  
Rapid Prototype ◽  
Layer By Layer ◽  
Forming Process ◽  
Rapid Prototype Technology ◽  
Nc System ◽  
Forming Technology ◽  
Dieless Forming

Sheet dieless digital forming is a new sheet metal dieless forming technology. This paper introduced the fundamentals of the Sheet dieless digital forming process. Based on the principle of “layered manufacture” in rapid prototype technology, this process resolves the intricate three-dimensional geometry information of the workpiece into a series of two-dimensional data, which can be used by an NC system to control a forming tool to make a curvilinear movement over the raw sheet metal layer by layer until the component wanted is formed. This paper introduced the Sheet dieless digital forming system and metal digital forming technology.

Study on the Manufacturing Technology of Directly Metal Forming Based on Overlay Welding

2014 ◽  
Vol 686 ◽  
pp. 22-25
Author(s):  
Li Min Zhang
Keyword(s):  
Metal Forming ◽  
Complex Shape ◽  
Three Dimensional ◽  
Rapid Prototype ◽  
Layer By Layer ◽  
Forming Process ◽  
Functionally Gradient ◽  
Metal Forming Process ◽  
Overlay Welding ◽  
Production Problems

Rapid prototyping technology can greatly improve the actual processing industrial prototype; this paper introduces the main principle, characteristics and technology of rapid prototype manufacturing. The current rapid prototype manufacturing products and production problems are analyzed. Because of the direct metal forming process have the characteristic of point by point, surfacing with stack molding manufacturing layer by layer, so it is suitable for complex shape parts two-dimensional or three-dimensional functionally gradient materials manufacturing.

Compensations for Tool Path to Enhance Accuracy During Double Sided Incremental Forming

2015 ◽  
Author(s):  
Rakesh Lingam ◽  
Anirban Bhattacharya ◽  
Javed Asghar ◽  
N. Venkata Reddy
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Incremental Sheet Metal Forming

Incremental Sheet Metal Forming (ISMF) is a flexible sheet metal forming process that enables forming of complex three dimensional components by successive local deformations without using component specific tooling. ISMF is also regarded as die-less manufacturing process and in the absence of part-specific dies, geometric accuracy of formed components is inferior to that of their conventional counterparts. In Single Point Incremental Forming (SPIF), the simplest variant of ISMF, bending near component opening region is unavoidable due to lack of support. The bending in the component opening region can be reduced to a larger extent by another variant of ISMF namely Double Sided Incremental Forming (DSIF) in which a moving tool is used to support the sheet locally at the deformation zone. However the overall geometry of formed components still has unacceptable deviation from the desired geometry. Experimental observation and literature indicates that the supporting tool loses contact with the sheet after forming certain depth. Present work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflection due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap that occurs during forming (instead of using sine law). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths.

Economical and Ecological Aspects of Single Point Incremental Forming Versus Deep Drawing Technology

2007 ◽  
Vol 344 ◽  
pp. 931-938 ◽  
Author(s):  
Aleš Petek ◽  
Gašper Gantar ◽  
Tomaz Pepelnjak ◽  
Karl Kuzman
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Deep Drawing ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Forming Technology ◽  
Ecological Aspects

In contemporary industrial production the ecological aspects have increasingly important role in selection of sheet metal forming process. To produce sheet metal parts with minimal environmental burdening the shortening of forming processes including the procedures for production of appurtenant forming tools as well as decrease use of lubricant is prerequisite. The ecological aspects have to be considered also already in developmental phase where the forming technology is evaluated in digital environment with FEM simulations. In addition, particularly in small and medium batch production the geometrically complex parts are difficult to form economically with conventional forming processes like deep drawing or stretching. Therefore, new concepts like hydro-mechanical forming or incremental sheet metal forming were developed. In order to select the optimal forming process the production costs as well as the environmental aspects like lubrication, noise, pollution and energy per produced part have to be considered. The paper is focused towards the comparison of conventional deep drawing (DD) process aimed for forming the pyramid-shaped part with single point incremental forming technology (SPIF). The economical and ecological aspects affecting the successful forming by both concepts are determined. Comparative evaluation was established in order to present advantages and drawbacks of each analysed technology.

A New Stretch-Forming Process Based on Loading at Discrete Points and its Numerical Investigation

2013 ◽  
Vol 423-426 ◽  
pp. 737-740
Author(s):  
Zhong Yi Cai ◽  
Mi Wang ◽  
Chao Jie Che
Keyword(s):  
Sheet Metal ◽  
Three Dimensional ◽  
Discrete Point ◽  
Stretch Forming ◽  
Sheet Metal Part ◽  
Metal Part ◽  
Forming Process ◽  
Loading Trajectory ◽  
New Process ◽  
Forming Defects

A new stretch-forming process based on discretely loading for three-dimensional sheet metal part is proposed and numerically investigated. The gripping jaw in traditional stretch-forming process is replaced by the discrete array of loading units, and the stretching load is applied at discrete points on the two ends of sheet metal. By controlling the loading trajectory at the each discrete point, an optimal stretch-forming process can be realized. The numerical results on the new stretch-forming process of a saddle-shaped sheet metal part show that the distribution of the deformation on the formed surface of new process is more uniform than that of traditional stretch-forming, and the forming defects can be avoided and better forming quality will be obtained.

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

Stress Analysis of Sheet Metal Vibration Incremental Forming

2010 ◽  
Vol 154-155 ◽  
pp. 166-170
Author(s):  
Gai Pin Cai ◽  
Ning Yuan Zhu ◽  
Na Wen
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Low Frequency ◽  
Forming Process ◽  
Technical Parameters ◽  
Vibration Technique ◽  
Low Frequency Vibration ◽  
Metal Deformation ◽  
Angle Effect ◽  
Forming Angle

As a non-homogenous force stresses during incremental forming, sheet metal easily tended to instability, and some defects, such as deposition, wrinkle and fracture, would appear. If the vibration technique was combined the incremental forming process, its deformation mechanism would be different from that of the old process, and sheet metal deformation quality was also risen. Then some mechanical equations were built by force analyzed on element in local contact zone of die head forcing down. According to reasonable hypothesis and simplified, the equations were solved. Some stress-time curves of the element were obtained by given process parameters, vibrational parameters and time parameters. It is shown from analysis that stress variety of the element is closely related to amplitude, frequency and forming angle, effect of sheet metal vibration incremental forming with high frequency vibration is more superior than that of with low frequency vibration; only when vibrational parameters are reasonably matching technical parameters, the effective vibration incremental forming can be obtained.

Flexible Stretch Forming Technology for Sheet Metal Based on Discrete-Gripper and Multi-Point Die

2014 ◽  
Vol 556-562 ◽  
pp. 460-463 ◽  
Author(s):  
Xue Chen ◽  
Ming Zhe Li ◽  
Wen Hua Liu ◽  
Zhi Qiang Hou
Keyword(s):  
Sheet Metal ◽  
Experimental Results ◽  
Shape Error ◽  
Stretch Forming ◽  
Forming Process ◽  
Structural Composition ◽  
Forming Technology ◽  
Working Principle ◽  
Material Utilization

To solve the problem of low material utilization in traditional stretch forming process, a flexible stretch forming method was proposed, which can be realized by interaction of the multi-point stretch forming die with discrete-gripper stretch forming machine. The principle and characteristics of sheet metal flexible stretch forming technology was introduced, structural composition and working principle of the multi-point stretch forming die and discrete-gripper stretch forming machine were expounded, and the technology experiments was carried out with a self-designed flexible stretch forming technology equipment for sheet metal. The experimental results indicate that structure of multi-point stretch forming die and discrete-gripper stretch forming machine are reasonable, and flexible stretch forming technology can be realized by above-mentioned die and machine, stretch forming parts has a good quality and its shape error can satisfy requirements of production.

Effects of Tool Deflection in Accumulated Double-Sided Incremental Forming Regarding Part Geometry

2016 ◽  
Author(s):  
Huaqing Ren ◽  
Newell Moser ◽  
Zixuan Zhang ◽  
Kornel F. Ehmann ◽  
Jian Cao
Keyword(s):  
Sheet Metal ◽  
Relative Position ◽  
Capital Investment ◽  
Incremental Forming ◽  
Position Angle ◽  
Tool Deflection ◽  
Geometric Accuracy ◽  
Localized Deformation ◽  
Forming Process ◽  
Part Geometry

Incremental forming is a flexible dieless forming process. In incremental forming, the metal sheet is clamped around its periphery. One or multiple generic stylus-type tools move along a predefined toolpath, incrementally deforming the sheet metal into a final, freeform shape. Compared with the traditional sheet metal forming process, the incremental forming process is more flexible, energy efficient and cost effective due to lower capital investment related to tooling. However, maintaining tight geometric tolerances in incremental formed parts can be a challenge. Specifically, undesired global bending is usually induced near the region between the tools and fixture resulting in a compromise in geometric accuracy. To address this issue, Accumulated Double-Sided Incremental Forming (ADSIF) is proposed, which utilizes two tools on both sides of the metal to better achieve localized deformation while simultaneously constraining global bending outside the forming area. Moreover, in ADSIF, the two tools are moving from inward to outward, and thus the tools are always forming virgin material and so as to limit forces on the already-formed part. Thus, ADSIF has a higher potential to achieve the desired geometry. Nevertheless, tool deflection due to machine compliance is still an issue that can have a considerable effect on geometric accuracy. In this work, the effect of tool deflection related to part geometry is studied for the ADSIF process. The nature of using two tools, rather than one, in ADSIF inherently implies that relative tool position is a critical process parameter. It is the region near these two tools where local squeezing and bending of the sheet occurs, the primary modes of deformation found in ADSIF. The change of relative tool positions (i.e., tool gap and relative position angle) are studied in detail by first developing an analytical model. It is concluded that the tool gap will be enlarged under the influence of tool compliance while the relative position angle is less affected. Additionally, a finite element simulation capable of modeling tool deflection is established. The comparison between the simulation results using rigid tools and deformable ones clearly demonstrated the significant influence of tool compliance on part geometry. Lastly, an axisymmetric part with varying wall angles was formed, and it was confirmed that ADSIF demonstrates improved geometry accuracy compared with conventional Double-Sided Incremental Forming.

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.

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