Single Point Incremental Sheet Forming of Polymer on Computer Numerically Controlled (CNC) Milling Machine Tool

2014 ◽  
Vol 622-623 ◽  
pp. 420-426 ◽  
Author(s):  
D. Rajenthirakumar ◽  
R. Sridhar
Keyword(s):  
Plastic Deformation ◽  
Sheet Metal ◽  
Failure Modes ◽  
Tool Path ◽  
Single Point ◽  
Research Work ◽  
Milling Machine ◽  
Forming Process ◽  
Tool Paths ◽  
Computer Numerically Controlled

The idea of incrementally forming sheet metal with a single point tool, called ‘dieless forming’, was patented by Leszak [1] well before it was technically feasible. There have been many studies, which have lead to the present situation [2-9]. The new processes are attractive because manufacturing sheet metal can be accomplished by any facility having a three-axiscncmill. Sheet metalspifis an innovative, flexible sheet metal-forming technology that uses principles of layered manufacturing. It transforms the complicated geometry information into a series of parameter of two-dimensional layers and then the plastic deformation is carried out layer-by-layer through the computer numerically controlled. The basic principle ofspif(Fig. 1) is that the forming tool moves around the outline of the part along the predefined tool path and extrudes the sheet metal point by point so that the local plastic deformations occur incrementally [8, 10]. The forming tool paths have a great effect on the surface quality, forming time and dimensional accuracy. Although the movement mode of the forming tool is similar to one of the cutters in thecncmilling machine, the forming process based on the plastic deformation and milling process is totally different, so the requirements for the tool paths are different. As a result, there are some specific characteristics which should be considered in forming tool path generation. The goal of this paper is to evaluate the possibility of producing low-cost polymer sheet components by means ofspif. Three different thermoplastic materials were incrementally formed on a conventionalcncmilling machine. Experiments are conducted to determine the formability, failure modes and significant process parameters. Even though considerable amount of research work has been done in the field, these aspects are not completely defined and only limited number of materials has been tested.

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.

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.

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.

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.

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.

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.

Preliminary Studies on the Determination of FLD for Single Point Incremental Sheet Metal Forming

2012 ◽  
Vol 504-506 ◽  
pp. 863-868 ◽  
Author(s):  
Miklos Tisza ◽  
Péter Zoltán Kovács ◽  
Zsolt Lukács
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
New Technologies ◽  
Single Point ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Forming Limit ◽  
Incremental Sheet Metal Forming

Development of new technologies and processes for small batch and prototype production of sheet metal components has a very important role in the recent years. The reason is the quick and efficient response to the market demands. For this reasons new manufacturing concepts have to be developed in order to enable a fast and reliable production of complex components and parts without investing in special forming machines. The need for flexible forming processes has been accelerated during the last 15 years, and by these developments the technology reaches new extensions. Incremental sheet metal forming (ISMF) may be regarded as one of the promising developments for these purposes. A comprehensive research work is in progress at the University of Miskolc (Hungary) to study the effect of important process parameters with particular emphasis on the shape and dimensional accuracy of the products and particularly on the formability limitations of the process. In this paper, some results concerning the determination of forming limit diagrams for single point incremental sheet metal forming will be described.

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.

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.

Principle and Simulation Study on Multi Point-Single Point Incremental Combined Forming for Sheet Metal

2009 ◽  
Vol 626-627 ◽  
pp. 273-278 ◽  
Author(s):  
X.J. Li ◽  
Ming Zhe Li ◽  
C.G. Liu ◽  
Zhong Yr Cai
Keyword(s):  
Sheet Metal ◽  
Single Point ◽  
Experimental Result ◽  
Work Piece ◽  
The Novel ◽  
Forming Process ◽  
Explicit Finite Element ◽  
Forming Defect ◽  
Forming Technology ◽  
Elastic Cushion

Based on Multi-Point (MP) forming technology and Single-Point Incremental (SPI) forming technology, MP-SPI combined forming method for sheet metal is proposed, the principle and two different forming techniques are illustrated firstly. Then the paper is focused on numerical analysis for the novel forming technique with explicit Finite Element (FE) algorithm. During simulation of spherical work-piece, dimpling occurs as a main forming defect in MP-SPI combined forming process. Simulation results show that the dimpling defect can be suppressed effectively by using elastic cushion. An appropriate thickness of elastic cushion is necessary to prevent dimpling. And also the deformation of the work-piece is sensitive to the shape of elastic cushion. The combined forming test shows that the numerical simulation result is closed to the experimental result.

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