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.

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 A recommendation of computation of normal streeses in single point incremental forming technology

2014 ◽  
Vol 17 (1) ◽  
pp. 21-28
Author(s):  
Dien Khanh Le ◽  
Nam Thanh Nguyen ◽  
Binh Thien Nguyen
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Incremental Forming ◽  
Single Point ◽  
Finite Element Method Simulation ◽  
Recent Decade ◽  
Work Piece ◽  
Single Point Incremental Forming ◽  
Forming Technology ◽  
Element Method

Single Point Incremental Forming (SPIF) has become popular for metal sheet forming technology in industry in many advanced countries. In the recent decade, there were lots of related studies that have concentrated on this new technology by Finite Element Method as well as by empirical practice. There have had very rare studies by pure analytical theory and almost all these researches were based on the formula of ISEKI. However, we consider that this formula does not reflect yet the mechanics of destruction of the sheet work piece as well as the behavior of the sheet in reality. The main aim of this paper is to examine ISEKI’s formula and to suggest a new analytical computation of three elements of stresses at any random point on the sheet work piece. The suggested formula is carefully verified by the results of Finite Element Method simulation.

Feature Based Approach for Increasing the Accuracy of the SPIF Process

2007 ◽  
Vol 344 ◽  
pp. 527-534 ◽  
Author(s):  
Johan Verbert ◽  
Joost R. Duflou ◽  
Bert Lauwers
Keyword(s):  
Surface Finish ◽  
Feature Detection ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Freeform Surfaces ◽  
Single Pass ◽  
Feature Based ◽  
Manufacturing Time ◽  
Achievable Accuracy

One of the main issues of the single point incremental forming (SPIF) process is still the achievable accuracy. A number of methods have been suggested to increase this accuracy, but many of these contain a significant drawback. Reprocessing the workpiece can increase the accuracy but also significantly increases the manufacturing time and leads to a worse surface finish of the part. Other methods iteratively correct the toolpath based upon the deviations measured on the previously manufactured parts. This method is not very well suited for one of a kind products, since instead of one part, multiple parts need to be manufactured before the desired accuracy can be reached. Our method proposes to use feature detection to split the workpiece in a configuration of planes, edges, freeform surfaces and other features. For each of these features an optimised toolpath strategy can be determined and the toolpath in that zone can be adjusted for this strategy. The proposed method generates a single pass toolpath that leads to more accurate parts compared to the standard CAM toolpaths. This paper describes the feature based optimised toolpath generation method (FSPIF) and contains the results of experiments performed to validate this method.

A Study on Using Cover Blank in Single Point Incremental Forming Process by Finite Element Analysis

2015 ◽  
Vol 809-810 ◽  
pp. 277-282
Author(s):  
Khalil Ibrahim Abass
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Sheet Material ◽  
Single Point ◽  
Complex Nature ◽  
Work Piece ◽  
Process Conditions ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Highly Nonlinear

The Single Point Incremental Forming Process (SPIF) is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped. The finished part is manufactured by the CNC machine. SPIF involves extensive plastic deformation and the description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. However, due to the complex nature of these models, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study on effect of using cover blank in SPIF through FEA. The considered SPIF has been studied under certain process conditions referring to the test work piece, tool, etc., applying ANSYS 11.0. The results show that the simulation model can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool-work piece, the product accuracy by evaluation its thickness and strain distributions, the contact status and chattering among surface interface tool-work piece.

Experimental thermal analysis and modelling of single point lathe cutting tools without cooling effect

2018 ◽  
Vol 7 (2) ◽  
pp. 276
Author(s):  
A. Agarwal ◽  
M.T Letsatsi ◽  
O.M. Seretse ◽  
R. Marumo
Keyword(s):  
Mild Steel ◽  
Feed Rate ◽  
High Speed ◽  
Single Point ◽  
Cutting Tools ◽  
Tool Material ◽  
High Speed Steel ◽  
Work Piece ◽  
Comparison Of Experiments ◽  
Tungsten Carbide Tool

This study investigated the use of tungsten carbide tool and high speed steel (HSS) tool when machining aluminum and mild steel. The parameters such as feed and speed of rotation were varied in order to observe their effect on machining operation. The experiments were performed without a coolant. FLIR thermo Cam P60 and Infra-Red Camera were used to record the observations. The highest temperature were recorded when feed rate was 2 mm. A comparison of experiments shows that HSS tooling produced high temperatures when machining mild steel. At 625 rev/min HSS failed when cutting mild steel at 2 mm feed rate. It was generally observed that temperatures generated between a tool and work piece is a function of feed rate, speed of rotation and tool material. These observations can aid the selection of a tool before a machining operation.

scholarly journals Die Design of Flexible Multi-Point Forming Process

2019 ◽  
Vol 14 (2) ◽  
pp. 22-29
Author(s):  
Tahseen Fadhel Abaas ◽  
Karem Mohsen Younis ◽  
Khalida Kadhim Mansor
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Setting Time ◽  
Die Design ◽  
Work Piece ◽  
Shape Error ◽  
Forming Process ◽  
Blank Holder ◽  
Flexible Manufacture ◽  
Minimum Force

Multi-point forming (MPF) is an advanced flexible manufacture technology, and the technology results from the idea that the whole die is separated into small punches that can be adjusted height. This idea is applied to the traditional rigid blank-holder, so flexible blank-holder (FBH) idea can be obtained. In this work, the performance of a multi-point die is investigated with pins in square matrix and suitable blank holder. Each pin in the punch holder can be a significant moved according to the die high and at different load that applied with spring with respect to spring stiffness. The results shows the reduction in setting time with respect to traditional single point incremental forming process that lead to (90%). and also show during the forming process, the deformation of the interpolator can induce a shape error in the formed work-piece and the blank holder can reduce/eliminate dimples that sometimes arise in the work-piece. The minimum force applied using multi-point die is 28.556KN, while the load when complete the forming process is 30.8KN that caused displacement of die to 32.8mm.

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

Performance of PVD Coated on High Speed Steel Cutting Tool in Industrial Applications

2014 ◽  
Vol 984-985 ◽  
pp. 495-501 ◽  
Author(s):  
R. Ravi Raja Malarvannan ◽  
T.V. Moorthy ◽  
M. Shunmuga Priyan
Keyword(s):  
Physical Vapor Deposition ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
High Speed Steel ◽  
Industrial Applications ◽  
Work Piece ◽  
Film Material ◽  
Quality Control Process ◽  
The Cost

An experimental investigation of mechanical properties of TiN and AlCrN Coated cutting tools have been performed at room Temperature. HSS single point cutting tool is taken as substrate material. Aluminium chromium nitride (AlCrN) and Titanium Nitride (TiN) is applied by physical vapour deposition method. Vaporized and condensed form of the desired film material on to various work piece surface is generally known as Physical Vapor Deposition (PVD). The finished product’s surface finish is increased by the coated tool and hence it reduces the cost of quality control process in industry. In uncoated HSS tool, the tool frequently requires replacement or reconditioning, which is not required for TiN and AlCrN Coated cutting tool and hence it reduces the cost for replacements .In PVD coating, the tool life is increased about 7.5 times compared to the uncoated cutting tool. For the factor of cost analysis, the cost required for making an AlCrN coated cutting tool is drastically reduced and increased life of tool also reduces the cost to procure a new tool or replacing an old one.

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.

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