Prediction of Tool Force in Two Point Incremental Forming by Slab Analysis

This paper is focused on the hybridization of additive manufacturing with single-point incremental forming to produce stiffening grooves in thin metal parts. An analytical model built upon in-plane stretching of a membrane is provided to determine the tool force as a function of the required groove depth and to estimate the maximum allowable groove depth that can be formed without tearing. The results for additively deposited stainless-steel sheets show that the proposed analytical model can replicate incremental plastic deformation of the stiffening grooves in good agreement with experimental observations and measurements. Anisotropy and lower formability caused by the dendritic-based microstructure of the additively deposited stainless-steel sheets justifies the reason why the maximum allowable depth of the stiffening grooves is approximately 27% smaller than that obtained for the wrought commercial sheets of the same material that are used for comparison purposes.

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Effect of hardening law and process parameters on finite element simulation of single point incremental forming (SPIF) of 7075 aluminum alloy sheet

Mechanics & Industry ◽

10.1051/meca/2020019 ◽

2020 ◽

Vol 21 (3) ◽

pp. 302 ◽

Cited By ~ 1

Author(s):

Rasoul Esmaeilpour ◽

Hyunki Kim ◽

Taejoon Park ◽

Farhang Pourboghrat ◽

Akshat Agha ◽

...

Keyword(s):

Process Parameters ◽

Strain Distribution ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming ◽

Effective Plastic Strain ◽

Step Size ◽

Hardening Law ◽

Element Simulation ◽

Tool Force

In the last two decades, the advances of using computers in sheet metal forming processes have introduced a novel adjustable process known as incremental sheet forming (ISF) as an optimal method for fast prototyping and low numbers of production. Formability and deformation behavior of ISF process are highly affected by the selected process parameters, such as the toolpath, step size, tool diameter, feed rate, and lubrication. The purpose of this work was to study the effect of these process parameters as well as hardening law on single point incremental forming (SPIF) process. For this work, a truncated-cone geometry was considered as a target shape with 7075-O aluminum alloy sheets. The simulations were conducted with different process parameters, i.e., toolpath type, step size, tool size, feed rate, friction coefficient, and wall angle with respect to the tool force and moment, effective plastic strain distribution and thickness of the part. In addition, three types of hardening laws i.e., isotropic extended Voce type hardening law, combined isotropic-kinematic Chaboche type hardening laws with single and double back-stress terms were applied in the finite element simulation of SPIF process. A detailed comparison of these hardening laws' predictions was made with respect to the tool force and moment, effective plastic strain distribution and thickness of the part.

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

Engineering and Technology Journal ◽

10.30684/etj.v38i8a.906 ◽

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.

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Hot single-point incremental forming assisted by induction heating

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-015-7439-x ◽

2015 ◽

Vol 82 (5-8) ◽

pp. 1163-1171 ◽

Cited By ~ 29

Author(s):

Amar Al-Obaidi ◽

Verena Kräusel ◽

Dirk Landgrebe

Keyword(s):

Induction Heating ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming

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A numerical approach for the modelling of forming limits in hot incremental forming of AZ31 magnesium alloy

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-07059-6 ◽

2021 ◽

Author(s):

Davide Campanella ◽

Gianluca Buffa ◽

Ernesto Lo Valvo ◽

Livan Fratini

Keyword(s):

Room Temperature ◽

Incremental Forming ◽

Material Model ◽

Numerical Approach ◽

Forming Limit ◽

Material Strength ◽

Wall Angle ◽

Analytical Expression ◽

The Poor ◽

Specific Material

AbstractMagnesium alloys, because of their good specific material strength, can be considered attractive by different industry fields, as the aerospace and the automotive one. However, their use is limited by the poor formability at room temperature. In this research, a numerical approach is proposed in order to determine an analytical expression of material formability in hot incremental forming processes. The numerical model was developed using the commercial software ABAQUS/Explicit. The Johnson-Cook material model was used, and the model was validated through experimental measurements carried out using the ARAMIS system. Different geometries were considered with temperature varying in a range of 25–400 °C and wall angle in a range of 35–60°. An analytical expression of the fracture forming limit, as a function of temperature, was established and finally tested with a different geometry in order to assess the validity.

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A high-fidelity simulation of double-sided incremental forming: Improving the accuracy by incorporating the effects of machine compliance

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2021.117152 ◽

2021 ◽

Vol 295 ◽

pp. 117152

Author(s):

Newell Moser ◽

Dohyun Leem ◽

Kornel Ehmann ◽

Jian Cao

Keyword(s):

Incremental Forming ◽

High Fidelity ◽

High Fidelity Simulation

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Investigations into Enhanced Formability of AA5083 Aluminum Alloy Sheet in Single-Point Incremental Forming

Journal of Materials Engineering and Performance ◽

10.1007/s11665-021-05455-3 ◽

2021 ◽

Vol 30 (2) ◽

pp. 1289-1305

Author(s):

Gautam Kumar ◽

Kuntal Maji

Keyword(s):

Aluminum Alloy ◽

Incremental Forming ◽

Single Point ◽

Alloy Sheet ◽

Single Point Incremental Forming ◽

Aluminum Alloy Sheet ◽

Aa5083 Aluminum Alloy

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Multi-point die electromagnetic incremental forming for large-sized sheet metals

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2020.12.022 ◽

2021 ◽

Vol 62 ◽

pp. 458-470

Author(s):

Fei Feng ◽

Jianjun Li ◽

Rongchuang Chen ◽

Liang Huang ◽

Hongliang Su ◽

...

Keyword(s):

Incremental Forming ◽

Sheet Metals

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

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/14644207211020401 ◽

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.

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