Design of Experiment for Incremental Forming of Artificial Skull on Titanium Grade 2

2014 ◽  
Vol 950 ◽  
pp. 103-108 ◽  
Author(s):  
Nuttaphong Sornsuwit ◽  
Sunthorn Sittisakuljaroen
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Factorial Design ◽  
Sheet Metal ◽  
Design Of Experiment ◽  
Incremental Forming ◽  
Forming Process ◽  
Titanium Grade ◽  
Main Effects ◽  
Full Factorial

The incremental forming process was investigated in this research for sheet metal. With this technique, it appeared in different surface roughness. This research studied a titanium grade 2 sheet, which is formed by incremental forming process with varied factors in the experimental design for Full Factorial Design 2-level for consideration of three factors determining the surface roughness. It was found that the factors of main effects to surface roughness were spindle speed and overlap. However, the depth did not affect directly on the surface roughness.

Interaction Relationship Analysis of Surface Roughness on Aluminium Etched Wafer Using RIE

2014 ◽  
Vol 487 ◽  
pp. 214-217
Author(s):  
Zaliman Sauli ◽  
Vithyacharan Retnasamy ◽  
Aaron Koay Terr Yeow ◽  
Ng Wei Wei
Keyword(s):  
Surface Roughness ◽  
Factorial Design ◽  
Design Of Experiment ◽  
Reactive Ion Etching ◽  
Full Factorial Design ◽  
Strong Interactions ◽  
Rf Power ◽  
Ion Etching ◽  
Relationship Analysis ◽  
Full Factorial

This paper presents the interaction relationships between Tetrafluoromethane (CF4) gas, Oxygen (O2) gas, and RF power in response to the surface roughness of an Aluminium deposited wafer after being etched using Reactive Ion Etching (RIE). The investigation was done using the three factors full factorial design of experiment (DOE). Analysis was done qualitatively by plotting the main interaction plots. The results suggest that strong interactions are present between CF4 and RF power, CF4 and O2, and also O2 and RF power due to the intersection of the graphs. This implies that all three factors have interaction between each other towards the surface roughness on the deposited Aluminium after RIE.

The Effected of Single Point Incremental Forming Process Parameters on the Formed Part Surface Roughness

2014 ◽  
Vol 979 ◽  
pp. 335-338
Author(s):  
Kittiphat Rattanachan ◽  
Chatchapol Chungchoo
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Process Parameters ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Tool Rotational Speed ◽  
Forming Process ◽  
Inner Surface

The single point incremental forming process (SPIF) are suited for sheet metal prototyping, because it is a low cost production process that produces sheet metal part without any used of die, and easy to adjust the part’s geometry by change toolpath. But the quality of forming parts is still in doubt. In some applications, such as mould cavity for rapid mould and the medical parts, in this case the inside surface roughness plays an importance role. In this paper, the SPIF process parameters that affected to the inner surface roughness were experimental studied. The investigated parameters are composing of tool feed rate, side overlap, depth step and tool radius. The 2k-p factorial experimental design was used to analyze the interaction between each parameter. The results showed that increasing feed rate and depth step decreased inner surface roughness. Reducing tool rotational speed and feed rate reduced inner surface roughness. So increasing depth step with decreasing side overlap reduced inner surface roughness. The large tool radius and lower side overlap improved inner surface roughness. The large tool radius and higher depth step improved inner surface roughness. And last, reducing tool rotational speed with larger tool radius, the inner surface roughness is decreased.

Wettability and Surface Roughness Study on RIE Treated Aluminium Deposited Surface

2014 ◽  
Vol 925 ◽  
pp. 101-104
Author(s):  
Vithyacharan Retnasamy ◽  
Zaliman Sauli ◽  
Uda Hashim ◽  
Moganraj Palianysamy ◽  
Aaron Koay Terr Yeow ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Contact Angle ◽  
Factorial Design ◽  
Process Parameters ◽  
Design Of Experiment ◽  
Etch Rate ◽  
Contact Angles ◽  
Atomic Force ◽  
Roughness Analysis ◽  
Full Factorial

Design of Experiment (DOE) is a technique for optimizing process which has controllable inputs and measurable outputs. As a method of DOE, 24 Full Factorial design is used to study the effect of Reactive Ion Etch towards the surface roughness of aluminum pad and effect of the roughness produced towards the contact angle. Surface roughness analysis is done using Atomic Force Microscop (AFM). Contact angle is measured using AutoCad software from the images captured from droplet test. This contact angles must be more than 90° for non-wetting profile or less than 90° for wetting profile. This work is also done to understand the interaction between the process parameters and how each parameters will affect the etch rate. The results are analyzed which shows that the increase in surface roughness produces an increase on the contact angle and vice versa.

Comparison of incremental sheet metal forming process using newly designed multipoint tool with the existing single point tool by optimization and characterization methods on austenite stainless steel 202

2021 ◽  
pp. 095440542098609
Author(s):  
Ramkumar Kathalingam ◽  
Baskar Neelakandan ◽  
Elangovan Krishnan ◽  
Sathiya Narayanan Chinnayan ◽  
Selvarajan Arangulavan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Research Work ◽  
Forming Process ◽  
Wall Angle ◽  
Incremental Sheet Metal Forming

Incremental Sheet metal Forming (ISF) is a reliable process of converting a blank to work piece with better outputs compared to conventional forming process. The flexibility of ISF in producing the rapid prototype based on the customer needs is increased which is also desirable in the industry. But Single Point Incremental Forming (SPIF) process takes more time to form a product and hence the longer time is a barrier in implementing this process in industries. In this research work, the ISF process was made on sheet metal SS 202 using a newly designed multi-point tool and the obtained outputs were compared with the same material of sheet metal formed by traditionally available single point tool. This Multi Point Incremental Forming (MPIF) process takes lesser process time to give better formability, improved wall angle and good surface roughness. The input process parameters selected for the process are type of tool, speed, feed, Vertical Step Depth (VSD), and lubrication. They are arranged by using the taguchi Design of Experiments (DOE) approach. The responses considered are wall angle, formability, surface roughness, spring back and forming time. The multiple outputs obtained were optimized by Grey Relational Analysis (GRA) to predict the superior parameter. Confirmation test was also made to validate the output result. Fractography analysis was carried out to predict the fracture mechanism obtained during the forming process. The surface topography was also made on the surface of the formed area of the sheet metal. This research work concludes that newly designed MPIF outperforms SPIF.

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.

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.

scholarly journals Common defects of parts manufactured through single point incremental forming

2021 ◽  
Vol 343 ◽  
pp. 04007
Author(s):  
Mihai Popp ◽  
Gabriela Rusu ◽  
Sever-Gabriel Racz ◽  
Valentin Oleksik
Keyword(s):  
Sheet Metal ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Serial Robot ◽  
The Many ◽  
Cold Metal

Single point incremental forming is one of the most intensely researched die-less manufacturing process. This process implies the usage of a CNC equipment or a serial robot which deforms a sheet metal with the help of a relatively simple tool that follows an imposed toolpath. As every cold metal forming process, besides the many given advantages it has also some drawbacks. One big drawback in comparison with other cold metal forming processes is the low accuracy of the deformed parts. The aim of this research is to investigate the sheet metal bending mechanism through finite element method analysis. The results shows that the shape of the retaining rings has a big influence over the final geometrical accuracy of the parts manufactured through single point incremental forming.

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