A Study of Forming Tool Profile Effect in Single Point Incremental Forming by Finite Element Analysis

2015 ◽  
Vol 760 ◽  
pp. 427-432
Author(s):  
Khalil Ibrahim Abass ◽  
Florian Draganescu
Keyword(s):  
Boundary Conditions ◽  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Material Behavior ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Tool Profile ◽  
Highly Nonlinear

The Single Point Incremental Forming Process, SPIF, is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped on fixture by holder. The finished part is performed by the CNC milling machine. The description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. Due to the fact that the mathematical analysis of SPIF is complex, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study concerning the effect of forming tool profile on SPIF through FEA, that permits the modeling of complex geometries, material behavior and boundary conditions. SPIF has been studied under certain process conditions referring to the test workpiece, tool, etc., using ANSYS 11.0. The results showed that the model of simulation can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool - workpiece, the accuracy of product by evaluation the strain and the stress distributions between forming tool and workpiece surface interface, and sample of results have been demonstrated.

A Study on Using Cover Blank in Single Point Incremental Forming Process by Finite Element Analysis

2015 ◽  
Vol 809-810 ◽  
pp. 277-282
Author(s):  
Khalil Ibrahim Abass
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Complex Nature ◽  
Work Piece ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Highly Nonlinear

The Single Point Incremental Forming Process (SPIF) is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped. The finished part is manufactured by the CNC machine. SPIF involves extensive plastic deformation and the description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. However, due to the complex nature of these models, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study on effect of using cover blank in SPIF through FEA. The considered SPIF has been studied under certain process conditions referring to the test work piece, tool, etc., applying ANSYS 11.0. The results show that the simulation model can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool-work piece, the product accuracy by evaluation its thickness and strain distributions, the contact status and chattering among surface interface tool-work piece.

A Study of Single Point Incremental Forming by Finite Element Analysis

2014 ◽  
Vol 657 ◽  
pp. 163-167 ◽  
Author(s):  
Khalil Ibrahim Abass
Keyword(s):  
Boundary Conditions ◽  
Incremental Forming ◽  
Single Point ◽  
Material Behavior ◽  
Complex Nature ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Element Analysis ◽  
Highly Nonlinear

The Single Point Incremental Forming Process (SPIF) involves extensive plastic deformation. The description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. The SPIF analysis is mathematically complex. However, due to the complex nature of these models, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study on SPIF through FEA, that permits the modeling of complex geometries, boundary conditions and material behavior. SPIF have been studied under certain process conditions referring to the test workpiece, tool, etc., using ANSYS 11.0. An important result is showing that the model of simulation can give as clearly the behavior of contact tool - workpiece and the effect it on strain and stress distributions, also on the accuracy of product. Relevant dependences between tool and workpiece surface interface and sample of results have been demonstrated.

scholarly journals Force Prediction for Correction of Robot Tool Path in Single Point Incremental Forming

2013 ◽  
Vol 554-557 ◽  
pp. 1282-1289 ◽  
Author(s):  
Jérémy Belchior ◽  
Dominique Guines ◽  
Lionel Leotoing ◽  
Eric Ragneau
Keyword(s):  
Input Data ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Element Analysis ◽  
Force Prediction ◽  
Material Parameters ◽  
Tool Path Correction ◽  
Machine Structure

In this work, an off-line compensation procedure, based on an elastic modelling of the machine structure coupled with a Finite Element Analysis (FEA) of the process is applied to Robotized Single Point Incremental Forming (RSPIF). Assuming an ideal stiff robot, the FEA evaluates the Tool Center Point (TCP) forces during the forming stage. These forces are then defined as an input data of the elastic robot model to predict and correct the tool path deviations. In order to make efficient the tool path correction, the weight of three numerical and material parameters of the FEA on the predicted forces is investigated. Finally, the efficiency of the proposed method is validated by the comparison between numerical and experimental geometries obtained with or without correction of the tool path.

Study on Process Parameters on Single Point Incremental Forming of PVC

2016 ◽  
Vol 878 ◽  
pp. 74-80 ◽  
Author(s):  
Xiao Bo Zhang ◽  
Jin Wang ◽  
Shu Qin Zhang
Keyword(s):  
Incremental Forming ◽  
Influencing Factor ◽  
Sheet Material ◽  
Single Point ◽  
Sheet Thickness ◽  
Feed Speed ◽  
Single Point Incremental Forming ◽  
Angle Variable ◽  
Material Forming ◽  
Material Wear

Effects of polyvinylchloride (PVC) sheet thickness (t), feed speed (υ), spindle speed (ω), Z-axis feed rate (p) and tool head diameter (Φ) as well as their interactions during the single point incremental forming (SPIF) on forming performance of the PVC sheet material were studied through an orthogonal experimental test. In this experiment, the angle-variable cone was used and the maximum forming limiting angle was taken as the experimental index. Results showed that and ω×Φ influence forming performance of PVC sheet material significantly. υ is the main influencing factor of SPIF performance of PVC sheet material. Small υ is good for sheet material forming. p and Φ are proportional to forming performance of sheet material. Over ω will cause material wear-out. Effect of t could be neglected.

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.

Drilled Hole Technique for Created Single Point Incremental Forming Limited Diagram

2015 ◽  
Vol 658 ◽  
pp. 177-181
Author(s):  
Kittiphat Rattanachan
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Single Point ◽  
Material Behavior ◽  
304 Stainless Steel ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Steel Blank ◽  
Etching Technique ◽  
Drilling Hole

To produce the forming limited diagram for predicting and studying material behavior in sheet metal forming, grid etching or grid marking on blank surface are applied before forming. But in single point incremental forming process, sheet metal blanks are subjected to highly strain or highly deformation which the conventional gridding is no longer to be occurred on the surface of formed part. And some material such as titanium, nickel based alloy etc are difficulty to etch the grid marks on its surface. So this paper is proposed the drilling hole technique to substitute with the grid etching technique in single point incremental forming process. The holes 2 mm. diameter were drilled on the SUS 304 stainless steel blank before forming. The deformed holes are calculated as true major strain and true minor strain and plot into a forming limited diagram. The results are compared with the conventional etching techniques which show an according trend. The drilling hole technique could be used in study the material behavior in single point incremental forming, it a low cost convenient and easy than grid etching technique.

scholarly journals Tool Path Design of the Counter Single Point Incremental Forming Process to Decrease Shape Error

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4719
Author(s):  
Kyu-Seok Jung ◽  
Jae-Hyeong Yu ◽  
Wan-Jin Chung ◽  
Chang-Whan Lee
Keyword(s):  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Optimization Method ◽  
Single Point Incremental Forming ◽  
Shape Error ◽  
Forming Process ◽  
Two Stage ◽  
Shape Errors

Incremental sheet metal forming can manufacture various sheet metal products without a dedicated punch and die set. In this study, we developed a two-stage incremental forming process to decrease shape errors in the conventional incremental forming process. The forming process was classified into the first single point incremental forming (1st SPIF) process for forming a product and the counter single point incremental forming (counter SPIF) process to decrease shape error. The counter SPIF gives bending deformation in the opposite direction. Furthermore, the counter SPIF compensates for shape errors, such as section deflection, skirt spring-back, final forming height, and round. The tool path of the counter SPIF has been optimized through a relatively simple optimization method by modifying the tool path of the previous step. The tool path of the 1st SPIF depends on the geometry of the product. An experiment was performed to form a circular cup shape to verify the proposed tool path of the 1st and counter SPIF. The result confirmed that the shape error decreased when compared to the conventional SPIF. For the application, the ship-hull geometry was adopted. Experimental results demonstrated the feasibility of the two-stage incremental forming process.

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