A General Method of Numerical Simulation for Incremental Forming

2011 ◽  
Vol 403-408 ◽  
pp. 4084-4088
Author(s):  
Li Jun Chen ◽  
Geng Pei ◽  
Qing Bo Fang ◽  
Jun Jie Pan
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Axial Stress ◽  
Thickness Distribution ◽  
Three Dimensional ◽  
Element Model ◽  
Simulation Method ◽  
Numerical Control ◽  
Nc Code ◽  
Tool Diameter

This paper presents a general simulation method for sheet metal incremental forming(ISF). Firstly, a three-dimensional finite element model based on Dynaform was developed to simulate the process. The tool path during the process simulation was directly defined by numerical control (NC) code and so identical with that in operation. Then, the results of numerical simulations with different process parameters, such as tool diameter, depth increment and wall angle, were discussed in details. The simulations reveal that with the decreasing depth step, increasing tool diameter and wall inclination angle, the axial stress reduces and leads to thinning reduction and more uniform thickness distribution. In addition, as the definition of the tool path was in accord with the genuine motion trajectory of the tool, the results deduced from this model may be more precise compared with those from other previously simplified models.

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.

Development of a 3D Cutter Compensation Postprocessor System for Multi-Axis Machining

2006 ◽  
Vol 505-507 ◽  
pp. 571-576 ◽  
Author(s):  
Chen Hua She ◽  
Chun Cheng Chang
Keyword(s):  
Tool Wear ◽  
Vector Function ◽  
Tool Path ◽  
Three Dimensional ◽  
Simulation Software ◽  
Numerical Control ◽  
Numerical Control Machining ◽  
Nc Code ◽  
G Code ◽  
Contour Machining

The compensation of tool wear is the important topics for numerical control machining. The lower-hand controller has the basic G code function (G41/G42) to obtain the compensated cutter location for planar contour machining. However, the advanced controller with cutter compensation vector function should be employed in order to process the three dimensional compensated tool path. The purpose of this paper is to establish the algorithm for calculating the 3D cutter compensation vector and develop a generalized postprocessor system to obtain the NC code. Through the verification by the solid cutting simulation software, it confirmed the effectiveness of the proposed algorithm.

Tool Path Optimization of 2D Contour Considering Stock Boundary

2012 ◽  
Vol 251 ◽  
pp. 169-172
Author(s):  
Fu Zhong Wu
Keyword(s):  
Present Method ◽  
Tool Path ◽  
Three Dimensional ◽  
Boundary Curve ◽  
Tool Path Generation ◽  
Path Optimization ◽  
Path Generation ◽  
Offset Curves ◽  
Measuring Machine ◽  
Tool Diameter

Based on analyzing the existing algorithms, a novel tool path generation of 2D contour considering stock boundary is presented. Firstly the boundary points of stock are obtained by three-dimensional measuring machine. And the boundary curve is constructed by method of features identifying. The stock boundary is offset toward outside with tool diameter. An enclosed region is formed between the contour curves and the offset curves of stock boundary. The tool path is generated by form of parallel spiral by offsetting the stock boundary in the enclosed region. Finally the validity of present method is demonstrated by an example.

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.

Study on the critical loosening condition toward a new design guideline for bolted joints

2018 ◽  
Vol 233 (9) ◽  
pp. 3302-3316 ◽  
Author(s):  
Hao Gong ◽  
Jianhua Liu ◽  
Xiaoyu Ding
Keyword(s):  
Three Dimensional ◽  
Element Model ◽  
Simulation Method ◽  
Bolted Joints ◽  
Design Guideline ◽  
Factors Affecting ◽  
Dimensional Finite Element ◽  
Frictional Coefficients ◽  
Three Dimensional Finite Element ◽  
Fit Tolerance

An understanding of conditions that trigger the loosening of bolted joints is essential to ensure joint reliability. In this study, a three-dimensional finite element model of a typical bolted joint is developed, and a new simulation method is proposed to quantitatively identify the critical transverse force for initiating loosening. This force is used to evaluate the anti-loosening capacity of bolted joints. Using the proposed simulation method, the effects of factors affecting critical loosening are systematically studied. It is found that the preload, frictional coefficients at the thread and the bearing surfaces, clamped length, and fit tolerance mainly affected loosening. When the preload and friction coefficients are increased, and the clamped length and fit tolerance are reduced, loosening is inhibited. Experiments are performed to demonstrate the reliability of the results. Finally, a suggestion is proposed to improve the design guideline VDI 2230 for bolted joints, which considers the requirement of avoiding loosening under vibrational loading.

Deformations Limits Analysis of Sheet Metal Manufatured through the Incremental Forming Process

2017 ◽  
Vol 899 ◽  
pp. 272-277
Author(s):  
Hugo Dutra Gomes ◽  
Maria Carolina dos Santos Freitas ◽  
Luciano Pessanha Moreira ◽  
Flavia de Paula Vitoretti ◽  
Jose Adilson de Castro
Keyword(s):  
Mechanical Properties ◽  
Finite Element Method ◽  
Finite Element ◽  
Tool Path ◽  
Incremental Forming ◽  
Numerical Control ◽  
Tool Geometry ◽  
The Finite Element Method ◽  
Forming Process ◽  
Contact Conditions

The present study is primarily engaged in the implementation of the incremental stamping process in a computerized numeric control This paper presents two different approaches to this forming process, an experimental and other numerical. Experimental used by the computer numerical control to perform the printing process and performs numerical simulations of the process using the finite element method. Some parameters are analyzed in both approaches, such as product geometry effects, tool geometry, tool speed, tool path, contact conditions and mechanical properties of the materials.

Inverse Design and Numerical Control Processing of the Little Bear Punch

2014 ◽  
Vol 687-691 ◽  
pp. 113-116
Author(s):  
Ge Zheng ◽  
Chun Wang ◽  
Bo Huang
Keyword(s):  
Geometric Modeling ◽  
Three Dimensional ◽  
Numerical Control ◽  
Inverse Design ◽  
Engineering Practice ◽  
Engineering Software ◽  
Nc Code ◽  
Three Dimensional Modeling ◽  
Machining Center ◽  
Means Of Measurement

Inverse design is the process of using a certain means of measurement to measure entity or model, and according to the measurements, refactoring physical CAD model through Three-dimensional geometric modeling methods. Basing on the little model, use reverse engineering methods, three-dimensional scanning technology and Raindrop Company produced the inverse engineering software to finish the reverse three-dimensional modeling design of little bear punch. Applying Master CAM to set parameters, simulation run, and automatically generate NC code, in the vertical machining center, complex curved surface NC machining of the model can be finished. In engineering practice, it can improve work efficiency, reduce the labor intensity of product development, and reduce the artificial error of the design.

Thickness Distribution and Forming Strategy Analysis for Two Point Incremental Forming with a Male Die

2011 ◽  
Vol 337 ◽  
pp. 452-455 ◽  
Author(s):  
Zhao Bing Liu ◽  
Paul Meehan ◽  
Paul Bellette
Keyword(s):  
Incremental Forming ◽  
Low Cost ◽  
Thickness Distribution ◽  
Single Point ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Strategy Analysis ◽  
Multi Stage ◽  
Analytical Perspective ◽  
Forming Strategy

Incremental Sheet Forming (ISF) is a promising sheet-metal-forming technology which is drawing more and more researchers’ attention due to its flexibility of manufacturing three-dimensional products at a relatively low cost for rapid prototyping and small-batch production. This paper is focused on the thickness distribution and the forming strategy analysis for two point incremental forming with a male die. The analyzed benchmark is half a torus which is generated by revolving a semi-circle. Such a part is hardly able to be formed by single point incremental forming because its slope varies from 0 degree to 90 degrees. In terms of the varying slope, the variant of sine’s law is derived to give an approximate prediction of the thickness distribution from an analytical perspective. In addition, a multi-stage forming strategy is proposed in order to form the part successfully. In particular, a keying operation is implemented carefully in order to avoid twist phenomenon and achieve good dimensional accuracy.

A Study on the Digital Simulation for Sheet Metal CNC Incremental Forming Based on Z-Map

2011 ◽  
Vol 201-203 ◽  
pp. 99-102
Author(s):  
Hu Zhu ◽  
Zhi Jun Liu ◽  
Jaegwan Kang
Keyword(s):  
Sheet Metal ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Digital Simulation ◽  
Simulation Models ◽  
Vertical Movement ◽  
Parameters Optimization ◽  
Nc Code ◽  
Cnc Incremental Forming ◽  
Swept Volumes

A method of the digital simulation for the sheet metal CNC incremental forming was proposed based on the Z-map model. The tool extrusion movements were divided into two types according to the principle of sheet metal CNC incremental forming, i.e. vertical movement and horizontal movement. The vertical and horizontal swept volumes of the tool were built to intersect with the Z-map model of sheet metal respectively and the simulation models were generated. The thickness of deformed sheet metal was predicted and the thickness distribution chart was generated. The case studies show that the method can be applied to NC code verification, forming parameters optimization and formability prediction, moreover the system runs stably and reliably in the whole simulation process.

scholarly journals Cranial Reconstruction Using Double Side Incremental Forming

2015 ◽  
Vol 639 ◽  
pp. 535-542 ◽  
Author(s):  
Bin Lu ◽  
Dong Kai Xu ◽  
Run Zhe Liu ◽  
Heng An Ou ◽  
Hui Long ◽  
...  
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Pure Titanium ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Backing Plate ◽  
Cranial Implant

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Comparing to conventional sheet forming processes, ISF is of a clear advantage in manufacturing small batch or customized products such as cranial implant. Although effort on cranial reconstruction by using incremental sheet forming approach has been made in recent years, research has been mostly based on the single point incremental forming (SPIF) strategy and there are still considerable technical challenges for achieving better geometric accuracy, thickness distribution and complex cranial shape. In addition, the use of a backing plate or supporting die reduces the process flexibility and increases the cost. To overcome these limitations, double side incremental sheet forming (DSIF) process is employed for forming Grade 1 pure titanium sheet by using different toolpath strategies. The geometric accuracy and thickness distribution of the final part are evaluated so the optimized tool path strategies are developed. This leads to an assessment of the DSIF based approach for the application in cranial reconstruction.

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