Surface and Microstructure Considerations in High Speed Single Point Incremental Forming of Ti6Al4V Sheets

2014 ◽  
Vol 611-612 ◽  
pp. 1071-1078 ◽  
Author(s):  
Giuseppina Ambrogio ◽  
Stefania Bruschi ◽  
Francesco Gagliardi ◽  
Andrea Ghiotti ◽  
Luigino Filice
Keyword(s):  
Metal Forming ◽  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
Heating Source ◽  
The Past ◽  
Process Configuration ◽  
Experimental Campaign ◽  
Application Potential ◽  
The Impact

Flexible sheet metal forming processes represent a big challenge, which involved a number of researchers all over the world in the last decades. Among these, Incremental Sheet Forming (ISF) process is one of the most investigated and promising due to its simplicity, cheapness and applicability. Furthermore, the possibility to increase the process velocity makes the ISF more suitable than in the past; as a consequence, its application potential is surely increased. It was already highlighted that high speed significantly raises the process temperature, improving the workability of Titanium alloys. In this process configuration, no further heating source is strictly required because the temperature increase is generated due to the plastic deformation and the friction conditions at the interface between the punch and the sheet. While the process feasibility has been already investigated, a lack of knowledge in the literature is present focusing on the analysis of the process impact on the material properties. Accordingly, an experimental campaign on Ti6Al4V sheets has been performed, considering a punch speed two orders of magnitude higher than the conventionally used one. The obtained surfaces have been compared to sheets worked by traditional velocity in order to accurately analyze the impact of high speed. Furthermore, microstructural analyses have been carried out confirming the high speed suitability. All the details are reported in the manuscript

On the high-speed Single Point Incremental Forming of titanium alloys

CIRP Annals ◽  
2013 ◽  
Vol 62 (1) ◽  
pp. 243-246 ◽  
Author(s):  
G. Ambrogio ◽  
F. Gagliardi ◽  
S. Bruschi ◽  
L. Filice
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming

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.

Incremental Roller-Flanging of Thick Metal Sheets

2021 ◽  
Vol 883 ◽  
pp. 209-216
Author(s):  
Andrea Ghiotti ◽  
Benvenuto Mattia del Tito ◽  
Enrico Simonetto ◽  
Stefania Bruschi ◽  
Stefano Filippi
Keyword(s):  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Metal Sheet ◽  
High Tech ◽  
Economic Competitiveness ◽  
Sheet Surface ◽  
Large Size ◽  
Metal Sheets ◽  
Innovative Concept

Metal forming industry is frequently characterized by the demand of small-batch productions to manufacture highly customized products. Apart from the accuracy that is mandatory in high-tech applications, one of the main requirements remains the economic competitiveness that becomes critical in the case of the deformation of thick metal sheets due to the relevant forming loads and the large size of the machines that are required to perform such processes. These problems are partially solved by using incremental forming approaches, in which the deformation is gradually performed by the use of one (single point) or two (double-sided) tools that are usually made to slide on the metal sheet surface while they impose the desired deformation. The paper aims at introducing an innovative concept of incremental forming machine to perform double-sided incremental bends, specifically developed for thick metal sheets. The increased flexibility and the possibility to manufacture sound parts with reduced bending forces are shown and discussed.

scholarly journals EFFECT OF FORMING TOOLS NOSE ON THE FORMABILITY OF SINGLE POINT INCREMENTAL SHEET FORMING.

2021 ◽  
Vol 21 (1) ◽  
pp. 1-14
Author(s):  
Entesar Nayyef Farhan
Keyword(s):  
Metal Forming ◽  
Room Temperature ◽  
Fe Simulation ◽  
Contact Region ◽  
Single Point ◽  
Spring Back ◽  
Incremental Sheet Metal Forming ◽  
Aluminum 7075 ◽  
Forming Tools ◽  
The Impact

In this paper the FE simulation and experimental equipment and design of the system for deformation by single point incremental sheet metal forming are presented. The formability is executed at room temperature and needs the milling machine, the tool of hemispherical head and toroidal head applied to deform the sheet, whereas translates from the peripheral of the sheet to its focus that additionally driving the sheet down. The blank is distorted increment by increment into the required shape via hemispherical or toroidal nose instrument going along a circular way. In the present investigation, the deformation’s analyses were down on the aluminum 7075 compound with thickness (0.9mm) and various device nose are enormously impact on the contact region and its observed that the hemispherical apparatus gives the best outcome. Close to this investigation consequence of the impact of shaping instrument nose on the formability is displayed. The ANSYS results are comparison with results obtained experimentally and it's discovered the deviation about 8% and this is expected to the criteria of spring-back.

Experimental Study on Residual Formability of Single Point Incrementally Formed Part

2019 ◽  
Author(s):  
Chetan P. Nikhare
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Forming Limit ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Conventional Process

Abstract A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

On the Effect of Curvature Radius on the Spif-Ability

2010 ◽  
Vol 129-131 ◽  
pp. 1222-1227 ◽  
Author(s):  
Ghulam Hussain ◽  
Gao Lin ◽  
Nasir Hayat ◽  
Asif Iqbal
Keyword(s):  
Sheet Metal Forming ◽  
Metal Forming ◽  
Incremental Forming ◽  
Single Point ◽  
Curvature Radius ◽  
Single Point Incremental Forming ◽  
Test Results ◽  
Forming Process ◽  
Wall Angle ◽  
Metal Forming Process

Single Point Incremental Forming (SPIF) is a novel sheet metal forming process. The formability (i.e. spif-ability) in this process is determined through Varying Wall Angle Conical Frustum (VWACF) test. In this paper, the effect of variation in the curvature radius, a geometrical parameter of test, on the test results is investigated. A series of VWACF tests with a variety of curvature radii is performed to quantify the said effect. It is found that the spif-ability increases with increasing of curvature radius. However, any variation in the curvature radius does not affect the spif-ability when the normalized curvature radius (i.e. curvature radius/tool radius) becomes higher than 9.

Brain Deformation in Linear Head Impact

2009 ◽  
Author(s):  
Kaveh Laksari ◽  
Kurosh Darvish
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Single Point ◽  
Arbitrary Lagrangian Eulerian ◽  
Brain Deformation ◽  
Ale Formulation ◽  
Point Integration ◽  
Inertial Loading ◽  
Experimental Values ◽  
The Impact

In this study, a 2D model of the head underwent linear impact and the experiments were simulated by finite element models. A cylinder with a diameter of 100mm and height of 20mm was filled with 5% gelatin, which was used as the brain surrogate material. The physical model was mounted onto a High Speed Computer Controlled Impact System to generate inertial loading of approximately 50 G average deceleration. The deformation of the samples was studied through image processing. Finite element (FE) analysis was used to simulate the experiments. The impact tests were modeled with two methods: a Lagrangian formulation with single point integration and an Arbitrary Lagrangian Eulerian (ALE) formulation with single point integration and void using LS-Dyna FE code. In the model with slip contact, the normal and shear strains reached more than 20% in some regions, which confirmed the risk of axonal injury in the linear impacts applied in this study. It was seen that in the Lagrangian models, in order to stabilize the simulation, high bulk moduli needed to be used; however, this resulted in much smaller void generation in the posterior region of the model. It was shown that the void generation reaches the experimental values by introducing 1–2 mm initial gaps between brain and skull. The ALE model was more stable and less sensitive to the bulk modulus, but showed smaller deformations.

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.

Negative Bulge Formation in High Speed Incremental Forming

2015 ◽  
Vol 639 ◽  
pp. 173-178 ◽  
Author(s):  
Hans Vanhove ◽  
Joost R. Duflou
Keyword(s):  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
Batch Size ◽  
Work Piece ◽  
Recent Developments ◽  
Bulge Formation ◽  
Specific Influence ◽  
Achievable Accuracy ◽  
Main Factor

As a flexible process, Single Point Incremental Forming has the potential to be widely used as a technique for prototyping, discrete or small batch production. However, its notorious lack of accuracy and formability limit a wide adoption on an industrial scale. While the main factor constraining the feasible batch size is the limited processing speed, recent developments towards High Speed SPIF have moved this restricting boundary considerably. Increased strain rates and friction in HS-SPIF introduce their own specific influence on the achievable accuracy. This paper aims to investigate the effect of HS-SPIF on the bulging of the bottom of a work piece. This explicit type of inaccuracy, also known as the pillowing effect, is mainly located in a region of the sheet which is to be left unprocessed, and is therefore challenging to eradicate. Different papers have focused on bulging of a sheet in conventional SPIF, resulting in knowledge about the inwards bending of the sheet at low wall angles. HS-SPIF, however, tends to show a previously unseen outwards bulge at high wall angles due to its unique thermal behavior.

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