Incremental Forming of AA8006 Aluminum Alloys Sheet with Different Step Size

2021 ◽  
Vol 1039 ◽  
pp. 137-143
Author(s):  
Ahmed M. Obaid ◽  
Jumaa S. Chiad ◽  
Ghanim Sh. Sadiq
Keyword(s):  
Incremental Forming ◽  
New Technology ◽  
Single Point ◽  
Strain Analysis ◽  
Sheet Forming ◽  
Metal Sheet ◽  
Strain Effect ◽  
Step Size ◽  
Hoop Strain ◽  
Long Time

The main objects of this paper are to deal with the new technology of metal sheet forming using the incremental single-point tool to form the sheet metal. However, due to the needed long time to form the metal in incremental so that we used punching and then incremental forming to geometry the final shape of the product. By measuring the thickness and longitudinal strain and evaluating the hoop strain, it was noticed that the less depth in punching with less step size in incremental forming have a better strain effect in metal sheet forming. Keywords: Single point, incremental forming, Strain analysis, step size.

A Research of the Precision of Titanium Sheet Formed by Hot Incremental Sheet Forming Method

2017 ◽  
Vol 749 ◽  
pp. 154-160
Author(s):  
Khanh Dien Le ◽  
Tan Hung Nguyen ◽  
Ngoc Huy Tran ◽  
Thanh Son Le ◽  
Huy Bich Nguyen ◽  
...  
Keyword(s):  
Empirical Process ◽  
Incremental Forming ◽  
New Technology ◽  
Single Point ◽  
Metal Sheet ◽  
Forming Process ◽  
Titanium Sheet ◽  
Metal Sheets ◽  
Experimental Process ◽  
Forming Angle

Single Point Incremental Forming (SPIF) is a recent technology of forming sheet in several decades. Nowadays, SPIF technology is still continued to be studied, applied and ameliorated in sheet manufacturing in industry. However one of the difficulties of the technology is the forming angle is still small (smaller than 800 according the properties of metal sheets). This paper recommends a measure of increasing the plasticity of the sheet by heating in time of forming by SPIF technology. Naturally, the plasticity of metal sheet increases by the temperature of the material in forming process with its limitation and constraint. The paper represents the effect of heating metal sheet through the empirical process of SPIF technology directed by the design of experiment (DOE). The analyses of the results of experimental process is applied to show the effect of heating to the precision of Titanium sheet. Finally, some private opinions about the heating in SPIF are also mentioned as a very tiny contribution of the research for the new technology.

Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

2020 ◽  
Vol 38 (8A) ◽  
pp. 1137-1142
Author(s):  
Baqer A. Ahmed ◽  
Saad K. Shather ◽  
Wisam K. Hamdan
Keyword(s):  
Vickers Hardness ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Coil Current ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

Multiobjective optimization of process variables in single-point incremental forming using grey relational analysis coupled with entropy weights

2021 ◽  
pp. 146442072110204
Author(s):  
Abdulmajeed Dabwan ◽  
Adham E Ragab ◽  
Mohamed A Saleh ◽  
Atef M Ghaleb ◽  
Mohamed Z Ramadan ◽  
...  
Keyword(s):  
Grey Relational Analysis ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Process Variables ◽  
Relational Analysis ◽  
Grey Relational

Incremental sheet forming is a specific group of sheet forming methods that enable the manufacture of complex parts utilizing computer numerical control instead of specialized tools. It is an incredibly adaptable operation that involves minimal usage of sophisticated tools, dies, and forming presses. Besides its main application in the field of rapid prototyping, incremental sheet forming processes can be used for the manufacture of unique parts in small batches. The goal of this study is to broaden the knowledge of the deformation process in single-point incremental forming. This work studies the deformation behavior in single-point incremental forming by experimentally investigating the principal stresses, principal strains, and thinning of single-point incremental forming products. Conical-shaped components are fabricated using AA1050-H14 aluminum alloy at various combinations of fundamental variables. The factorial design is employed to plan the experimental study and analysis of variance is conducted to analyze the results. The grey relational analysis approach coupled with entropy weights is also implemented to identify optimum process variables for single-point incremental forming. The results show that the tool diameter has the greatest effect on the thinning of the SPIF product, followed by the sheet thickness, step size, and feed rate.

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.

Analytical Computing Stresses and Strains in Single Point Incremental Forming

2019 ◽  
Vol 825 ◽  
pp. 129-139
Author(s):  
Le Khanh Dien ◽  
Le Khanh Tan ◽  
Van Thanh Nguyen ◽  
Huy Bich Nguyen ◽  
Thanh Nam Nguyen
Keyword(s):  
Incremental Forming ◽  
New Technology ◽  
Single Point ◽  
Fem Simulation ◽  
Recent Decade ◽  
Analytical Framework ◽  
Single Point Incremental Forming ◽  
Normal Stresses ◽  
Forming Technology ◽  
Almost All

Nowadays, Single Point Incremental Forming (SPIF) has become popular for metal sheet forming technology in industry in many advanced countries. In the recent decade, many relative studies have concentrated on this new technology of forming sheet by Finite Element Method (FEM) as well as by empirical way. There were very rare studies by pure analytical computing and P.A.F. Martins et al. under a title “Theory of single point incremental forming” performed almost all these researches were based on the analytical framework of SPIF in 2008. After careful studying on this research, we found out its light illogical result: the stresses inside of a random point in the workpiece sheet are constant and not related to the coordinate of the formed point of the sheet. Therefore, it cannot explain the mechanism of rupture and tear of the sheet that is really a serious restriction of the SPIF technology nowadays. This paper dedicates to suggest a new version of pure analytical computing the normal stresses at a random formed point in the sheet that could explain the tear mechanism and a FEM simulation was also carried out also to prove the conviction of the recommended formula.

Parameter optimization and texture evolution in single point incremental sheet forming process

2019 ◽  
Vol 234 (1-2) ◽  
pp. 126-139 ◽  
Author(s):  
Shamik Basak ◽  
K Sajun Prasad ◽  
Amarjeet Mehto ◽  
Joy Bagchi ◽  
Y Shiva Ganesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Regression Models ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Input Process ◽  
Truncated Cone

Prototyping through incremental sheet forming is emerging as a latest trend in the manufacturing industries for fabricating personalized components according to customer requirement. In this study, a laboratory scale single-point incremental forming test setup was designed and fabricated to deform AA6061 sheet metal plastically. In addition, response surface methodology with Box–Behnken design technique was used to establish different regression models correlating input process parameters with mechanical responses such as angle of failure, part depth per unit time and surface roughness. Correspondingly, the regression models were implemented to optimize the input process parameters, and the predicted responses were successfully validated at the optimal conditions. It was observed that the predicted absolute error for angle of failure, part depth per unit time and surface roughness responses was approximately 0.9%, 4.4% and 6.3%, respectively, for the optimum parametric combination. Furthermore, the post-deformation responses from an optimized single point incremental forming truncated cone were correlated with microstructural evolution. It was observed that the peak hardness and highest areal surface roughness of 158 ± 9 HV and 1.943 μm, respectively, were found near to the pole of single-point incremental forming truncated cone, and the highest major plastic strain at this region was 0.80. During incremental forming, a significant increase in microhardness occurred due to grain refinement, whereas a substantial increase in the Brass and S texture component was responsible for the increase in the surface roughness.

Comparison of the Geometric Accuracy by DSIF Toolpath with SPIF Toolpath

2014 ◽  
Vol 494-495 ◽  
pp. 497-501 ◽  
Author(s):  
Jin Han Wu ◽  
Qiu Cheng Wang
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Metal Sheet ◽  
Single Point Incremental Forming ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Forming Accuracy ◽  
Finite Method

As there is no sufficient support between the single moving tool and fixture, the formed metal sheet is easy to bend in single point incremental forming (SPIF). Double sided incremental forming (DSIF) is proposed in which two tools are used on each side of the sheet to improve the components forming accuracy. Element finite method is introduced to simulate the forming process with both DSIF and SPIF toolpaths and the component geometric accuracies are compared. The simulation result shows the DSIF toolpaths can obtain better geometric accuracy than SPIF.

Single Point Incremental Forming Limits Using a Boxbehnken Design of Experiment

2007 ◽  
Vol 344 ◽  
pp. 629-636 ◽  
Author(s):  
M. Ham ◽  
J. Jeswiet
Keyword(s):  
Design Of Experiment ◽  
Incremental Forming ◽  
Single Point ◽  
Response Surfaces ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Forming Limits ◽  
Box Behnken Design ◽  
Five Factors ◽  
Incremental Step

Single Point Incremental Forming (SPIF) is a new method of forming sheet metal for which not all forming limits and forming parameters are yet completely understood. In this paper, a Box-Behnken design of experiment (DOE) is used to execute an experimental study used to determine the forming limits in Single Point Incremental Forming (SPIF). The Box-Behnken allows for good accuracy in defining a surface response for a relatively low number of experimental runs – hence its usefulness in experimental work. The Box-Behnken used in this paper solved five factors at three levels in forty six runs. The five factors analyzed are based on the most critical factors effecting SPIF; they are material type, material thickness, formed shape, tool size and incremental step size (depth of each step in form). The data resulting from the Box-Behnken progressed into graphical response surfaces; the response surfaces allow designers to determine what factors they need to select in order to successfully form a part using SPIF.

scholarly journals Cranial Reconstruction Using Double Side Incremental Forming

2015 ◽  
Vol 639 ◽  
pp. 535-542 ◽  
Author(s):  
Bin Lu ◽  
Dong Kai Xu ◽  
Run Zhe Liu ◽  
Heng An Ou ◽  
Hui Long ◽  
...  
Keyword(s):  
Tool Path ◽  
Incremental Forming ◽  
Thickness Distribution ◽  
Single Point ◽  
Pure Titanium ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Geometric Accuracy ◽  
Backing Plate ◽  
Cranial Implant

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. Comparing to conventional sheet forming processes, ISF is of a clear advantage in manufacturing small batch or customized products such as cranial implant. Although effort on cranial reconstruction by using incremental sheet forming approach has been made in recent years, research has been mostly based on the single point incremental forming (SPIF) strategy and there are still considerable technical challenges for achieving better geometric accuracy, thickness distribution and complex cranial shape. In addition, the use of a backing plate or supporting die reduces the process flexibility and increases the cost. To overcome these limitations, double side incremental sheet forming (DSIF) process is employed for forming Grade 1 pure titanium sheet by using different toolpath strategies. The geometric accuracy and thickness distribution of the final part are evaluated so the optimized tool path strategies are developed. This leads to an assessment of the DSIF based approach for the application in cranial reconstruction.

Brass 70/30 and Incremental Sheet Forming Process

2013 ◽  
Vol 554-557 ◽  
pp. 1419-1431 ◽  
Author(s):  
Daniel Fritzen ◽  
Anderson Daleffe ◽  
Jovani Castelan ◽  
Lirio Schaeffer
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Cnc Machining ◽  
Forming Process ◽  
Wall Angle ◽  
Machining Center ◽  
Cad Cam ◽  
Cnc Machining Center

This work addresses through bibliographies and experiments the behavior of sheet brass 70/30 for Incremental Sheet Forming process - ISF, based on the parameters: wall angle (), step vertical (ΔZ) strategy and the way the tool. Experiments based on the method called Single Point Incremental Forming - SPIF. For execution of practical tests, we used the resources: software CAD / CAM, CNC machining center with three axles, matrix incremental, incremental forming tool and a device press sheets. Furthermore, measurement was made of the true deformation () and thickness (s1). Practical tests have shown that the spiral machining strategy yielded a greater wall angle, compared to the conventional strategy outline.

Sign in / Sign up

Export Citation Format

Share Document