Experimental Tests to Study Feasibility and Formability in Incremental Forming Process

2009 ◽  
Vol 410-411 ◽  
pp. 391-400 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Antonio Fiorentino ◽  
Luca Mazzoni ◽  
Claudio Giardini
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Experimental Tests ◽  
Final Part ◽  
Cnc Machine ◽  
Forming Process ◽  
Metal Forming Process ◽  
Sheet Formability

This paper deals with Incremental Sheet Forming (ISF), a sheet metal forming process, that knew a wide development in the last years. It consists of a simple hemispherical tool that, moving along a defined path by means of either a CNC machine or a robot or a self designed device, locally deforms a metal sheet. A lot of experimental and simulative researches have been conducted in this field with different aims: to study the sheet formability and part feasibility as a function of the process parameters; to define models able to forecast the final sheet thickness as a function of the drawing angle and tool path strategy; to understand how the sheet deforms and how formability limits can be defined. Nowadays, a lot of these topics are still open. In this paper, the results obtained from an experimental campaign performed to study sheet formability and final part feasibility are reported. The ISF tests were conducted deforming FeP04 deep drawing steel sheet 0.8 mm thick and analyzing the influence of the tool path strategy and of the adopted ISF technique (Single Point Incremental Forming Vs. Two Points Incremental Forming). The part feasibility and formability were evaluated considering final sheet thickness, geometrical errors of the final part, maximum wall angle and depth at which the sheet breaks. Moreover, process forces measurements were carried out by means of a specific device developed by the Authors, allowing to obtain important information about the load acting on the deforming device and necessary for deforming sheet.

Comparison between SPIF with Robot and CNC Machine

2011 ◽  
Vol 473 ◽  
pp. 929-936 ◽  
Author(s):  
Aldo Attanasio ◽  
Elisabetta Ceretti ◽  
Claudio Giardini ◽  
Silvio Antonioni
Keyword(s):  
Degrees Of Freedom ◽  
Tool Path ◽  
Sheet Material ◽  
Sheet Thickness ◽  
Cnc Machine ◽  
Forming Process ◽  
Advantages And Disadvantages ◽  
Shape Errors ◽  
Metal Forming Process ◽  
Sheet Formability

This paper deals with Incremental Sheet Forming (ISF) a sheet metal forming process that knew a wide development in the last years. A lot of experimental and simulative researches have been conducted in this field with different aims: to study the sheet formability and part feasibility; to define models able to forecast the final sheet thickness; to understand how the sheet deforms and how formability limits can be defined. Another very important issue is related with the tool path optimization. In fact, the process is characterized by high springback which causes dimensional defects. When IF is performed by a robot, the capabilities of the technology is improved in terms of obtainable shapes (it is possible to use the 6 degrees of freedom of the robot), but the shape errors seem to be higher due to the lower robot stiffness in comparison with CNC machine. In this work the comparison between two different ISF configurations, tool mounted on a CNC machine or tool mounted on a robot, is reported. A suitable geometry was investigated working different sheet material types and sheet thicknesses. The results in terms of geometrical accuracy and sheet deformation have been analyzed in order to define advantages and disadvantages of these two techniques. An analysis on the process forces has been carried out too.

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.

Incremental Forming Process for the Accomplishment of Automotive Details

2007 ◽  
Vol 344 ◽  
pp. 559-566 ◽  
Author(s):  
A. Governale ◽  
A. Lo Franco ◽  
A. Panzeca ◽  
Livan Fratini ◽  
Fabrizio Micari
Keyword(s):  
Automotive Industry ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Innovation Process ◽  
Forming Process ◽  
Metal Forming Process ◽  
New Methodologies ◽  
Auto Body ◽  
Aluminium Sheets

In the last decades the scenario of the industrial production is remarkably changed, since new market requirements have to be faced by the industries. The market, actually, more and more, asks for vary models and niches product. The necessity to intercept dynamically and to satisfy the demands for the market, driver of the innovation process, involves the necessity to reduce the Timeto- market introducing to new methodologies of engineering, like the 3D-prototyping, for the qualitative and structural analysis of the final component. For these reasons, at the beginning of the nineties, a new philosophy of sheet metal forming process begins to assert on the industrial scene, whose basic logic is to obtain the shape wished through the progressive action of a tool of simple shape. In this job the application of the simplest process of incremental process on an industrial detail - famous in international field like SPIF (Single Point Incremental Forming) - will be described. The process is intrinsically flexible, and therefore is adapted to the rapid prototyping. The cases are still least, notice in the scientific literature, in which the details of industrial interest have been developed by Incremental Forming process; for this reason, the subject of this job is focused on the evaluation of the possibility to obtain real components of the automotive industry through the SPIF process. The job has been carried out in the R&D laboratory of "Fontana Pietro S.p.A.”, leader in the field of die manufacturing and stamping of component of the automotive industry. In particular, two parts of automotive auto body of aluminium sheets have been considered. It has been lead an analysis of technological and process feasibility, optimizing tool path considering experiences to obtain a product/process for the production of auto body prototypes.

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

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Lingam Rakesh ◽  
Srivastava Amit ◽  
N. V. Reddy
Keyword(s):  
Deformation Zone ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Sheet Plane ◽  
Support Tool ◽  
Metal Forming Process

Incremental sheet forming (ISF) is a flexible sheet metal forming process that enables forming of complex three-dimensional components by successive local deformations without using component-specific tooling. ISF is also regarded as a die-less manufacturing process in the absence of part-specific die. Geometric accuracy of formed components is inferior to that of their conventional counterparts. In single-point incremental forming (SPIF), the simplest variant of ISF, 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 ISF, 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 indicate that the supporting tool loses contact with the sheet after forming certain depth. This work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflections due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap of deformation zone that occurs during forming (instead of using sine law). A number of examples are presented to show that the proposed methodology works for a variety of geometries (axisymmetric, varying wall angle, free-forms, features above and below initial sheet plane, and multiple features). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths using DSIF, and support tool maintains contact with sheet throughout the forming process.

Study of Tool Trajectory in Incremental Forming

2012 ◽  
Vol 472-475 ◽  
pp. 1586-1591 ◽  
Author(s):  
S.H. Wu ◽  
Ana Reis ◽  
F.M. Andrade Pires ◽  
Abel D. Santos ◽  
A. Barata da Rocha
Keyword(s):  
Damage Mechanics ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Continuum Damage Mechanics ◽  
Work Piece ◽  
Processing Parameter ◽  
Forming Process ◽  
Tool Paths ◽  
Metal Forming Process

Single point incremental forming (SPIF) is an innovative flexible sheet metal forming process which can be used to produce complex shapes from various materials. Due to its flexibility, it attracts a more and more attention in the recent decades. Several studies show that besides the major operating parameters, namely feed rate, tool radius, and forming speed etc., tool path is also an important processing parameter to affect the final forming component. In view of that, the present paper studies the influence of tool paths on the work piece quality by the finite element method coupled with the Continuum Damage Mechanics (CDM) model. The formability of incremental forming in different tool paths is also analyzed.

scholarly journals PROCESS SIMULATION AND QUALITY EVALUATION IN INCREMENTAL SHEET FORMING

2011 ◽  
Vol 12 (3) ◽  
Author(s):  
Meftah Hrairi ◽  
Salah B. M. Echrif
Keyword(s):  
Wall Thickness ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Low Cost ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Metal Forming Process ◽  
Complex Parts

Single Point Incremental Forming (SPIF) is a promising sheet-metal-forming process that permits the manufacturing of small to medium-sized batches of complex parts at low cost. It allows metal forming to work in the critical ‘necking-to-tearing' zone which results in a strong thinning before failure if the process is well designed. Moreover, the process is complex due to the number of variables involved. Thus, it is not possible to consider that the process has been well assessed; several remaining aspects need to be clarified. The objective of the present paper is to study some of these aspects, namely, the phenomenon of the wall thickness overstretch along depth and the effect of the tool path on the distribution of the wall thickness using finite element simulations.Abstrak: Pembentukan Tokokan Mata Tunggal (Single Point Incremental Forming (SPIF)) merupakan satu proses pembentukan kepingan logam yang membolehkan pembuatan dalam jumlah yang kecil hingga sederhana, bahagian-bahagian yang kompleks pada kos yang rendah. Jika proses ini direka dengan baik, kaedah ini membolehkan pembentukan logam yang baik terhasil. Jika tidak, semasa peringkat zon kritikal ‘perleheran-ke-pengoyakan' menyebabkan penipisan keterlaluan yang boleh menyebabkan logam tersebut rosak. Tambahan pula, proses ini agak kompleks, kerana ia melibatkan beberapa pemboleh ubah. Maka, walaupun proses ini telah dinilaikan seeloknya; masih terdapat beberapa aspek lain yang perlu diperjelaskan. Objektif kertas ini dibentangkan adalah untuk mengkaji beberapa aspek tertentu, seperti, ketebalan dinding regangan berlebihan di sepanjang kedalaman dan kesan tool path (beberapa siri posisi koordinat untuk menentukan pergerakan alatan memotong ketika operasi memesin) terhadap pengagihan ketebalan dinding menggunakan simulasi unsur terhingga.

A Comparative Study of Simulation Models on Incremental Forming Process by Using the Enhancement Tools

2019 ◽  
Vol 957 ◽  
pp. 93-102
Author(s):  
Khalil Ibrahim Abass
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Simulation Models ◽  
Local Deformation ◽  
Process Models ◽  
Cnc Machine ◽  
Forming Process ◽  
Product Profile ◽  
Complex Forms

Incremental Forming IF is a suitable sheet metal forming technique for producing complex forms by local deformation. The forming tool movement follows the designed tool path controlled by the CNC machine programme. The main categories of the process are single point, SP and two points, TP "with enhancement tools". Additionally, the product design determines the enhancement tool type used and its obstacles. The enhancement tools are used for improvement of the product profile quality, while maintaining the simplicity of the process. The material formability is affected by mechanical properties and characteristics of the product profile. The limits are concerning the forming tools used and the blank thickness. On the other hand, due to the difficult environment of these process models, numerical methodologies controlled by Finite Element Method, FEM are currently in extensive use. The research offers the main data and results of a comparing study on the influence of using the enhancement tools in IF through FEM. The study purposes to identify the scientific differences of the IF processes, "with and without enhancement tools" by evaluating the thickness and strains distribution of the deformed blank section. In addition, the analysis and the evaluation of the final product profile have been studied.

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 Simulation of incremental forming processes of a pyramidal ring made of two materials

2018 ◽  
Vol 19 (3) ◽  
pp. 313
Author(s):  
Masood Ghassabi ◽  
Milad Salimi ◽  
Mohammad Haghpanahi
Keyword(s):  
Feed Rate ◽  
Rotational Speed ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Cnc Machine ◽  
Forming Force ◽  
Forming Process ◽  
Dimensional Precision

Incremental forming is one of the most well-known forming processes for complex and asymmetric parts. This method uses a CNC machine, simple forming tool, and a die. This study focused on effects of some parameters such as the material, feed rate, pitch, rotational speed and movement strategy of tool on the dimensional precision, forming force, thickness distribution and fracture in the welding area. The results showed that single point incremental forming (SPIF) led to a better thickness distribution with lower tool force, whereas two-point incremental forming led to better dimensional accuracy. Rotational speed does not have any significant impact on the forming process while decreasing the feed rate partially reduced the forming force. According to the results, although dimensional precision in double point incremental forming is better than SPIF, when it comes to the thickness distribution, forming force, and economic issues, SPIF is in favor. The results also showed that by connecting two materials, different parameters for the two materials could be investigated simultaneously in one simulation process.

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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