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Journal articles on the topic 'Incremental sheet forming tool'
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1
Chezhian Babu, S., and V. S. Senthil Kumar. "Investigations on Incremental Forming of Low Carbon Steel Sheets." Applied Mechanics and Materials 26-28 (June 2010): 340–46. http://dx.doi.org/10.4028/www.scientific.net/amm.26-28.340.
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Low carbon steel sheets are used invariably in automobile body panels and construction structural applications. Conventional forming techniques require forming dies and heavy duty presses to make required shapes, which are costly in manufacturing. Incremental forming is a recently developing die less sheet metal part production technique in which the necessary part is obtained by gradually tracing its contours on a sheet of required thickness using stepwise tool indents. In this investigation, Low carbon steel sheets of different thicknesses were incrementally formed using a hemispherical tool under varying step depths. The final thickness of the sheet, forming angle, roughness and microhardness of the formed shapes were characterized. The microstructure of the formed materials was studied using optical microscope.
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Meier, Horst, V. Smukala, O. Dewald, and Jian Zhang. "Two Point Incremental Forming with Two Moving Forming Tools." Key Engineering Materials 344 (July 2007): 599–605. http://dx.doi.org/10.4028/www.scientific.net/kem.344.599.
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This paper describes a new development of an incremental, robot based sheet metal forming process for the production of sheet metal components for limited-lot productions and prototypes. The kinematic based generation of the shape is implemented by means of two industrial robots, which are interconnected to a cooperating robot system. Compared to other incremental sheet metal forming machines this system offers a high geometrical form flexibility without the need of any workpiece dependent tools. The principle of the procedure is based on flexible shaping by means of a freely programmable path-synchronous movement of two robots. So far, the final shape is produced by the incremental infeed of the forming tool in depth direction and its movement along the contour in lateral direction on each level. The counter tool, with its simple geometry, was used to support the sheet metal on the backside by moving synchronously along the outer contour, constantly on the same level. This corresponds to a fixed backplate used in other incremental sheet metal forming processes. Due to the use of a new robot system with extended control algorithms for cooperating robots, it will be possible to release the counter tool from its constant path on the outer contour and support the forming tool right on the opposite side of the sheet to generate a predefined gap between the two hemispherical tools. This way at each moment a small part of a full die, as it is used in other processes, is simulated without the need of producing a workpiece dependent die. The extended payload of the new robot system gives the opportunity to form steel blanks, for the first time.
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HINO, R., F. YOSHIDA, N. NAGAISHI, and T. NAKA. "INCREMENTAL SHEET FORMING WITH LOCAL HEATING FOR LIGHTWEIGHT HARD-TO-FORM MATERIAL." International Journal of Modern Physics B 22, no. 31n32 (December 30, 2008): 6082–87. http://dx.doi.org/10.1142/s0217979208051613.
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A new incremental sheet forming technology with local heating is proposed to form lightweight hard-to-form sheet metals such as aluminum-magnesium alloy (JIS A5083) sheet or magnesium alloy (JIS AZ31) sheet. The newly designed forming tool has a built-in heater to heat the sheet metal locally and increase the material ductility around the tool-contact point. Incremental forming experiments of A5083 and AZ31 sheets are carried out at several tool-heater temperatures ranging from room temperature to 873K using the new forming method. The experimental results show that the formability of A5083 and AZ31 sheets increases remarkably with increasing local-heating temperature. In addition, springback of formed products decreases with increasing local-heating temperature. The developed incremental sheet forming method with local heating has great advantages in not only formability but also shape fixability. It is an effective forming method for lightweight hard-to-form sheet metal for small scale productions.
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Fritzen, Daniel, Anderson Daleffe, Jovani Castelan, and Lirio Schaeffer. "Brass 70/30 and Incremental Sheet Forming Process." Key Engineering Materials 554-557 (June 2013): 1419–31. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1419.
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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.
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Sajjad, Muhammad, Jithin Ambarayil Joy, and Dong Won Jung. "Finite Element Analysis of Incremental Sheet Forming for Metal Sheet." Key Engineering Materials 783 (October 2018): 148–53. http://dx.doi.org/10.4028/www.scientific.net/kem.783.148.
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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.
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Siddiqi, Muftooh Ur Rehman, Jonathan R. Corney, Giribaskar Sivaswamy, Muhammad Amir, and Rahul Bhattacharya. "Design and validation of a fixture for positive incremental sheet forming." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 4 (April 19, 2017): 629–43. http://dx.doi.org/10.1177/0954405417703423.
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Incremental sheet forming is an emerging manufacturing technique in which sheet metal is formed into desired shape through the application of localized force using a hemispherical tool. Potential advantages of the process are its relatively low cost and small lead times, and these have to be balanced against the disadvantages of low dimensional accuracy and a limited understanding of the process’ internal mechanics. Incremental sheet forming system can be classified as positive, or negative, depending on whether the sheet material is progressively deformed onto a protrusion or a cavity. In negative systems, the work piece is held on a static fixture; whereas, in positive incremental sheet forming, the fixture must be incrementally lowered onto a protruding die. Although the vertical movement of positive incremental sheet forming fixtures is easily illustrated schematically, its implementation is challenging; if the descent is actuated, the motion has to be carefully coordinated with those of the forming tool; if free sliding on vertical columns, the rig must move without jamming or rocking. This article reports the development and testing of a positive incremental sheet forming fixture design that uses nylon sleeve bushes. Symmetric and asymmetric components were formed using the designed fixture, modular wooden dies and a rotating tool with multiple diameters and the results are discussed.
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Sieczkarek, Peter, Lukas Kwiatkowski, A. Erman Tekkaya, Eugen Krebs, Petra Kersting, W. Tillmann, and Jan Herper. "Innovative Tools to Improve Incremental Bulk Forming Processes." Key Engineering Materials 554-557 (June 2013): 1490–97. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1490.
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Sheet-bulk metal forming is an innovative process with a high potential to generate load-adapted parts with high precision. Bulk forming processes of sheet metals especially require high process forces, resulting in an intense contact pressure and, thus, in a very high abrasive and adhesive wear. As a method to reduce or avoid these common wear phenomena, even hardened or coated tool surfaces are not sufficient. The objective of this paper is to show an improvement of the tool resistance during an incremental forming process by an adapted tool design and the application of structured tool surfaces combined with coatings. For the tool surface the structure of the scarabaeus beetle serves as the basis for a bionic structure. This structure was manufactured by micromilling. Despite the high hardness of the tool material and the complex geometry of the forming tools, very precise patterns were machined successfully using ball-end milling cutters. The combination of bionic structures with coating techniques like physical vapor deposition (PVD) on plasma nitrided tool surfaces is very promising. In this work, the influence of process parameters (workpiece material, lubrication, tool design, stepwise infeed) on the tool resistance during the forming operation was analyzed experimentally. The results of the optimized forming tools were compared to conventional, unstructured, uncoated, and only plasma nitrided forming tools. The different tools were applied to 2 mm thick metal sheets made of aluminum (AlMg3) and steel (non-alloy quality steel DC04). As a result, the process forces could be reduced by a modified shape and surface of the tools. Thus, the lifetime of the tools can be enhanced.
8
Vahdati, Mehdi, Ramezanali Mahdavinejad, and Saeid Amini. "Investigation of the ultrasonic vibration effect in incremental sheet metal forming process." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 231, no. 6 (April 8, 2015): 971–82. http://dx.doi.org/10.1177/0954405415578579.
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The mechanism of incremental sheet metal forming is based on plastic and localized deformation of sheet metal. The sheet metal is formed using a hemispherical-head tool in accordance with the path programmed into the computer numerical control milling machine controller. Experimental and numerical analyses have been performed previously on the application of ultrasonic vibration to various metal forming processes. However, thus far, the effects of ultrasonic vibration on incremental sheet metal forming have not been investigated. This article presents the process of design, analysis, manufacture and testing of a vibrating forming tool for the development of ultrasonic vibration–assisted incremental sheet metal forming. The results obtained from modal analysis and natural frequency measurement of the vibrating tool confirmed the emergence of a longitudinal vibration mode and resonance phenomenon in the forming tool. Then, the effect of ultrasonic vibration on incremental sheet metal forming was studied. The obtained experimental results from the straight groove test on Al 1050-O sheet metals showed that ultrasonic vibration led to decrease in the following parameters as compared with conventional incremental sheet metal forming: applied force on forming tool axis, spring-back and surface roughness of formed sample.
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Galdos, Lander, Eneko Sáenz de Argandoña, Nagore Otegi, and Rafael Ortubay. "Incremental Forming of Sandwich Materials." Key Engineering Materials 504-506 (February 2012): 931–36. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.931.
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In the last decade, a completely new process has been developed using the existing knowledge in machining and in flow forming and spinning processes, so called the Incremental Sheet Forming. In the process, a spherical tool, governed by CNC incrementally forms a sheet metal to form complex and asymmetric parts using minimum tooling. Several works have been published to study the process limits, optimization of paths for the forming of deep walls and to extent the formability of some alloys using temperature as a process variable. Few studies have been also published where the incremental forming of polymers has been studied. In this work, the forming of steel-polymer-steel hybrid material or Laminate Vibration Damping Steels (LVDS) is considered. Spinnability tests are used to study the process limits and the effects of having two independent sheets in the thickness of the initial blank. The maximum forming angle, forming vertical force and maximum strains near the fracture are presented for the sandwich material in comparison to steel with three different thicknesses and same composition.
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Otsu, Masaaki. "Excellent Formability of Light Metals Sheets by Friction Stir Incremental Forming." Key Engineering Materials 716 (October 2016): 3–10. http://dx.doi.org/10.4028/www.scientific.net/kem.716.3.
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The results about friction stir incremental forming of light metals sheets from the beginning of development to the latest in the author’s laboratory are introduced. Comparison of formability by the conventional single point incremental sheet metal forming and friction stir incremental forming for magnesium alloys, aluminum alloys and titanium sheets were introduced. Effect of tool rotation direction, multistage forming and double side forming are also introduced.
11
Bedan, Aqeel Sabree, and Halah Ali Habeeb. "Experimental Study the Effect of Tool Geometry on Dimensional Accuracy in Single Point Incremental Forming (SPIF) Process." Al-Nahrain Journal for Engineering Sciences 21, no. 1 (February 10, 2018): 108. http://dx.doi.org/10.29194/njes21010108.
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Incremental forming is a flexible sheet metal forming process which performed by utilizes simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. One limitations of single point incremental forming (SPIF) process is the error occur between the CAD design and the product profile. This work presents the single point incremental forming process for produced pyramid geometry and studied the effect of tool geometry, tool diameter, wall angle, and spindle speed on the dimensional accuracy. Three geometries of forming tools were used in experimental work: ball end tool, hemispherical tool, and flat with round corner tool. The sheet material used was pure Aluminum (Al 1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The products dimensions were measured by utilized the dimensional sensor measuring instrument. The extracted results from the single point incremental forming process indicated the best acceptance between the CAD profile and product profile was found with the ball end tool and diameter of (10 mm), wall angle (50°) and the rotational speed of the tool was (800 rpm).
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Josue da Silva, Pablo, and Alberto J. Alvares. "Investigation of tool wear in single point incremental sheet forming." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234, no. 1-2 (April 24, 2019): 170–88. http://dx.doi.org/10.1177/0954405419844653.
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This article presents a proposal for a new method to evaluate tool wear incremental sheet forming process. Incremental sheet forming is an innovative forming process with a high interest in fields of the industry due to its low preparation cost and high flexibility, allowing the production of small batches at a reduced cost. Among the various types of incremental sheet forming processes, the single point incremental sheet forming is the most cost-effective, and unfortunately, the single point incremental sheet forming process has high dimensional errors. In order to understand the process and its dimensional errors better, this article shows the study of tool wear and the quality of surface finish with the generated data can correlate with the tool life. The study is carried out by means of a sequence of experimental tests of galvanized steel sheet conformation by altering the stamping parameters (vertical step in, feed and rotation) and capturing the values of the surface roughness of the parts, the forming tool wear and processing time. After the completion of the tests, the classical formulation of the Taylor equation was utilized to obtain a mathematical model capable of estimating the lifetime of the single point incremental sheet forming tool associated with a tool wear value and the desired dimensional accuracy in relation to the processing parameters for the part or tool pair analyzed in a computer numerical control machine tool. The results of the study present an original model of prediction of tool wear in relation to the input parameters for the single point incremental sheet forming process; the overall error rate is 33.44% for the wear model of prediction and 35.94% for the lifetime model of prediction.
13
Zhu, Hu, Wen Wen Lin, and Jin Lan Bai. "An Overview of the Sheet Metal CNC Incremental Forming Toolpath Generation." Advanced Materials Research 503-504 (April 2012): 35–39. http://dx.doi.org/10.4028/www.scientific.net/amr.503-504.35.
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The sheet metal CNC incremental forming is a flexible dieless forming technology that forms a sheet part by extruding the sheet metal point by point with the movement of forming tool along the forming path. The tool paths therefore have a great effect on the dimensional accuracy, surface quality and forming time. In this paper, an overview of the research status about the forming tool path generation for sheet metal CNC incremental forming is presented briefly.
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Formisano, Antonio, Luca Boccarusso, Luigi Carrino, Massimo Durante, Antonio Langella, Fabrizio Memola Capece Minutolo, and Antonino Squillace. "Formability and Surface Quality of Incrementally Formed Grade 1 Titanium Thin Sheets." Key Engineering Materials 716 (October 2016): 99–106. http://dx.doi.org/10.4028/www.scientific.net/kem.716.99.
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The incremental forming of titanium alloy sheets combines the advantages of this advanced flexible manufacturing process, that allows to produce complex components without using dedicated tools, with the interesting properties of the material under consideration. In this study, thin sheets of grade 1 titanium were incrementally formed to evaluate their formability and surface quality by varying the tool-sheet contact conditions. Experimental tests and surface analyses highlight dependence on the contact conditions of the surface quality rather than of the formability. Moreover, they emphasize that the tool-sheet contact conditions mainly affect the repeatability of the process due to the occurrence of galling.
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Giraud-Moreau, Laurence, Abel Cherouat, Jie Zhang, and Houman Borouchaki. "Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results." Key Engineering Materials 554-557 (June 2013): 1375–81. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1375.
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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.
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Centeno, Gabriel, Isabel Bagudanch, María Luisa García-Romeu, Andrés Jesús Martínez-Donaire, and Carpóforo Vallellano. "Experimental Study on the Overall Spifability of AISI 304 Sheets under Different Bending Conditions." Key Engineering Materials 554-557 (June 2013): 2293–98. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.2293.
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In this paper the influence of the bending effect in the formability of AISI 304 metal sheets in incremental forming is analyzed. For this purpose, a series of single point incremental forming tests were carried out using a variety of tool diameters and step downs. The spifability (formability in single point incremental sheet forming) of the metal sheets was studied in the light of circle grid analysis by means of the 3D deformation digital measurement system ARGUS®. The results show the importance of the bending effect, induced by the tool radius, in the enhancement of formability in incremental forming compared to conventional forming processes.
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Sieczkarek, Peter, Lukas Kwiatkowski, A. Erman Tekkaya, Eugen Krebs, Dirk Biermann, Wolfgang Tillmann, and Jan Herper. "Improved Tool Surfaces for Incremental Bulk Forming Processes of Sheet Metals." Key Engineering Materials 504-506 (February 2012): 975–80. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.975.
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Sheet-bulk metal forming is a process used to manufacture load-adapted parts with high precision. However, bulk forming of sheet metals requires high forces, and thus tools applied for the operational demand have to withstand very high contact pressures, which lead to high wear and abrasion. The usage of conventional techniques like hardening and coating in order to reinforce the surface resistance are not sufficient enough in this case. In this paper, the tool resistance is improved by applying filigree bionic structures, especially structures adapted from the Scarabaeus beetle to the tool’s surface. The structures are realized by micromilling. Despite the high hardness of the tool material, very precise patterns are machined successfully using commercially available ball-end milling cutters. The nature-adapted surface patterns are combined with techniques like plasma nitriding and PVD coating, leading to a multilayer coating system. The effect of process parameters on the resistance of the tools is analyzed experimentally and compared to a conventional, unstructured, uncoated, only plasma nitrided forming tool. Therefore, the tools are used for an incremental bulk forming process on 2 mm thick metal sheets made of aluminum. The results show that the developed methodology is feasible to reduce the process forces and to improve the durability of the tools.
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Mohammadi, Amirahmad, Hans Vanhove, Albert van Bael, Dieter Weise, and Joost R. Duflou. "Formability Enhancement in Incremental Forming for an Automotive Aluminium Alloy Using Laser Assisted Incremental Forming." Key Engineering Materials 639 (March 2015): 195–202. http://dx.doi.org/10.4028/www.scientific.net/kem.639.195.
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The aim of this study is to establish general guidelines for minimizing the number of tests required to determine optimum process parameters in terms of formability for laser assisted single point incremental forming (LASPIF). An automotive aluminium alloy (AA5182-O) is selected and the room temperature failure angle of this material is determined experimentally. The straining behaviour as well as sheet thinning of the test part (at its maximum forming angle) is studied using an experimentally validated finite element model. From the thinning rate of the sheet metal and the shape of the contact zone between tool and sheet it is concluded that continuous straining of the sheet on the wall region of the contact area is responsible for extra thinning and failure. Based on the size and position of the contact zone, different laser tool positioning strategies have been used to achieve the highest forming angle. It is concluded that due to an elongated shape of the contact zone in steep wall angle parts and considering a small deviation of the forming robot, the selection of a large spot diameter is necessary in terms of maximum obtainable wall angle. It has been observed that the maximum forming angle is still achievable using a large forward offset. It is concluded that the partial stress-relief annealing of the deformed geometry during the approach of the forming tool, is responsible for this formability enhancement.
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Jackson, K. P., J. M. Allwood, and M. Landert. "Incremental Forming of Sandwich Panels." Key Engineering Materials 344 (July 2007): 591–98. http://dx.doi.org/10.4028/www.scientific.net/kem.344.591.
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This paper presents a first investigation of the applicability of incremental sheet forming (ISF) to sandwich panels. Two initial tests on various sandwich panel designs established that sandwich panels which are ductile and incompressible are the most suitable for the process. Further tests on a sandwich panel with mild steel face plates and a continuous polypropylene core demonstrated that patterns of deformation and tool forces followed similar trends to a sheet metal. It is concluded that, where mechanically feasible, ISF can be applied to sandwich panels using existing knowledge of sheet metals with the expectation of achieving similar economic benefits. Potentially this will increase the range of applications for which sandwich panels are viable.
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Meier, Horst, and Christian Magnus. "Incremental Sheet Metal Forming with Direct Resistance Heating Using Two Moving Tools." Key Engineering Materials 554-557 (June 2013): 1362–67. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1362.
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This paper describes new developments in an incremental, robot-based sheet metal forming process (‘Roboforming’) for the production of sheet metal components in small batch sizes. The dieless kinematic-based generation of a shape is implemented by means of two industrial robots which are interconnected to a cooperating robot system. Compared to other incremental sheet metal forming machines, this system offers high geometrical form flexibility without the need of any part-dependent tools. The industrial application of incremental sheet metal forming is still limited by certain constraints, e.g. the low geometrical accuracy and number of formable alloys. One approach to overcome the stated constraints is to use the advantages of metal forming at elevated temperatures. For the temperature input into the sheet metal, there are different approaches like heating with warm fluids, a laser beam or using direct resistance heating. This paper presents results of the research project ‘Local heating in robot-based incremental forming’, funded by the German Research Foundation (DFG), where the heating of the current forming zone by means of direct resistance heating is examined as a variation of the Roboforming process. In order to achieve a local limitation of the heating on the current forming zone, the electric current flows into the sheet at the electric contact of the forming tool and the sheet metal. Thus the forming tool is part of the electric circuit. In current literature Authors report about results from experiments using single-point incremental forming, where the forming tool and the clamping frame of the sheet are connected to the power source. In order to further limit the heating on the forming zone, a new approach will be presented in this paper, where a second tool is used to support the forming and heating process, as both tools can be connected to the power source, making a current flow through the rest of the sheet and the clamping frame unnecessary. With the use of two tools the current flow and thus the heated zone of the sheet can be manipulated. Additionally the advantages of the supporting tool, already shown in forming at room temperature, such as increased geometrical accuracy and maximum draw angle can be used. Starting with a description of the new process setup for steel forming at about 600 °C, results of experiments evaluating the influence of the supporting tool on the forming process at elevated temperatures and the resulting geometrical accuracy will be presented in this paper. Therefore, different process parameters as forming temperature, cooling and relative positioning of the both tools have been varied.
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Zhou, Liu Ru. "Study on the Surface Quality of Fender NC Incremental Forming." Advanced Materials Research 335-336 (September 2011): 523–26. http://dx.doi.org/10.4028/www.scientific.net/amr.335-336.523.
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The NC incremental sheet metal forming technology is a flexible forming technology without dedicated forming dies. The forming locus of the forming tool can be adjusted by correcting the numerical model of the product. Because the deformation of sheet metal only occurs around the tool head and the deformed region is subjected to stretch deformation, the deformed region of sheet metal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheet metal deformation. The principle of NC incremental sheet metal forming and the forming process of the fender are introduced. The effect of process parameters on forming is analysed. The improvement method of the forming quality is suggested. The groove is created in the starting point of tool moving when the starting point of tool moving locus at all layers is identical. The groove can be eliminated when the starting point of tool moving locus at all layers is different. The feed pitch p increase, the process time decrease, production rate and surface degree of roughness increase. In general, the feed pitch is 0.25mm.
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Lamminen, L. "Incremental Sheet Forming with an Industrial Robot – Forming Limits and Their Effect on Component Design." Advanced Materials Research 6-8 (May 2005): 457–64. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.457.
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Incremental sheet forming (ISF) has been a subject of research for many research groups before. However, all of the published results so far have been related to either commercial ISF machines or ISF forming with NC mills or similar. The research reported in this paper concentrates on incremental sheet forming with an industrial robot. The test equipment is based on a strong arm robot and a moving forming table, where a sheet metal blank is attached. The tool slides on the surface of the sheet and forms it incrementally to the desired shape. The robot is capable of 5-axis forming, which enables forming of inwards curved forms. In this paper the forming limit diagram (FLD) for ISF with the robot is presented and it is compared with conventional forming limit diagrams. It will be shown that the conventional FLD does not apply to incremental forming process. Geometrical accuracy of sample pieces is also studied. Cones of different shapes are formed with the robot equipment and their correspondence with the 3D CAD model is evaluated. The results are compared with other results of accuracy of incremental sheet forming, reported earlier by other researchers. The third issue covered in this article is a product development point of view to incremental sheet forming. In addition to fast prototyping and low volume production of sheet metal parts, ISF brings new possibilities to sheet metal component design and manufacturing. These possibilities can only be exploited if design rules, that will take the possibilities and limitations of the method into account are created for ISF.
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Allwood, J. M., N. E. Houghton, and K. P. Jackson. "The Design of an Incremental Sheet Forming Machine." Advanced Materials Research 6-8 (May 2005): 471–78. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.471.
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A new incremental sheet forming machine has been built in Cambridge and was commissioned in October 2004. The basis for the machine design is described, including estimates of tool forces, the need for access to the reverse side of the workpiece, and the need to cope with high horizontal loads at the tool tip. The tool-mounting has been designed to rotate freely but passively, and to allow for simple exchange of tool tips. The workpiece is mounted on a set of load cells providing a six degree of freedom constraint without moment loading of the cells. The initial operation of the machine is briefly described.
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Dejardin, Steeve, Jean Claude Gelin, and Sebastien Thibaud. "Experimental Investigations and Numerical Analysis for Improving Knowledge of Incremental Sheet Forming Process for Sheet Metal Parts." Materials Science Forum 623 (May 2009): 37–48. http://dx.doi.org/10.4028/www.scientific.net/msf.623.37.
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The paper is related to the analysis of shape distortions and springback effects arising in Single Point Incremental Forming. An experimental set up has been designed and manufactured to carry single point incremental forming on small size sheet metal parts. The experimental set up is mounted on 3-axes CNC milling machine tool and the forming tool is attached and move with the spindle. Experiments have been carried out on sheet metal parts to obtain tronconical shapes. The forming strategy associated to the movement of the forming tool has been also investigated. The experiments indicate that shape distortions arising in the corners of the tronconical shape are clearly related to forming strategy. The springback of rings cut in the tronconical parts have been also investigated. It is shown that positive or negative springback could be also related to forming strategy. In order to enhance experimental investigations, Finite Element simulations of the incremental sheet forming have been performed. Results obtained from the simulations prove that if boundary conditions and forming strategy carefully are taking into account, the finite elements results are in good agreement with experiments. So it is then possible to use FEM as a design tool for incremental sheet forming.
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Zhou, Liu Ru. "Study of Sphere NC Sheet Metal Incremental Forming." Advanced Materials Research 239-242 (May 2011): 1036–39. http://dx.doi.org/10.4028/www.scientific.net/amr.239-242.1036.
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The principle of NC incremental sheet metal forming as well as the process planning, experiment of sphere forming are presented. Because the deformation of sheet metal only occurs around the tool head and the deformed region is subjected to shear deformation and thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheet metal deformation. According to sine law, a sphere can’t be formed by NC incremental sheet metal forming process in a single process, rather, it must be formed in multi processes. Thus, the two time path process method is presented to form the sphere, and the experiment is made to verify it. A sphere can be formed from a sheet metal in NC incremental forming process by choosing appropriate tool-path planning. The fracture in the forming component can be avoided by these methods. A sphere of uniform wall-thickness can be formed from the truncated cone by NC incremental forming process.
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Daleffe, Anderson, Lirio Schaeffer, Daniel Fritzen, and Jovani Castelan. "Analysis of the Incremental Forming of Titanium F67 Grade 2 Sheet." Key Engineering Materials 554-557 (June 2013): 195–203. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.195.
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Analysis of a formed metal sheet shows the data of the incremental forming process. Variation in sheet deformation results from the process and shows how forming occurred. Another important result is the surface roughness of the sheet, which reports the parameters of the process, machine and tool used. Incremental forming of the titanium CP-Ti grade 2 sheet was performed in the SPIF modality – forming without a point of support, in order to look at the thickness deformations. SPIF incremental forming is characterized as forming that does not use points of support, and therefore simple tooling is used in the process. The following resources were used to perform the practical tests: CAD/CAM software, CNC machining center, incremental die, incremental forming tool and a sheet press device. The results obtained were the finish of the formed surface, measured by the roughness parameter RZ, and the measurement of the true strains ( ) and thickness (s1). Practical tests showed that the limit wall angle ( ), for the CP Ti grade 2 sheet, 0.5 mm thick, is 47º.
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Jeswiet, J., David J. Young, and M. Ham. "Non-Traditional Forming Limit Diagrams for Incremental Forming." Advanced Materials Research 6-8 (May 2005): 409–16. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.409.
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Although not standard, Forming Limit Diagrams, FLD’s, are used throughout the automotive industry as a preliminary tool to determine if a sheet metal forming process is capable of forming a good part. FLD’s show a limited range of strains on the diagram; typically the range is 0 to 1 on the major strain axis. A new rapid prototyping process called Single Pont Incremental Forming, SPIF, experiences strains over 3. As FLD’s do not typically cover that level of strain, a new method for developing FLD’s is needed. Such a method is proposed in this paper. Research has been conducted with five different shapes, formed using Single Point Incremental Forming. The part shapes utilized contain the most common combinations of angles and curves observed in formed sheet metal products. The strains encountered in forming each of these parts are measured and the strain data is then plotted on the same FLD. These new FLD’s can then be utilized as a predictive tool for engineers to determine if their design can be produced using the SPIF process.
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Zhou, Liu Ru. "The Effect of Forming Half-Apex Angle on Incremental Sheet Metal Forming." Advanced Materials Research 139-141 (October 2010): 1514–17. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.1514.
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The incremental sheet metal forming technology is a flexible forming technology without dedicated forming dies. The locus of the forming tool can be adjusted by correcting the numerical model of the product. The effect of forming half-apex angle on forming process with all kind of sheet material, sheet thickness and ironing ratio is researched. The limit half-apex angle is different for all kind of sheet material and thickness. The limit half-apex angle is smaller for the larger thickness of sheet metal. It will succeed in square conical box incremental forming in a single tool-path if the forming is carried out with an angle which is larger than the forming limit half-apex angle θ. The ironing ratio ψt is decided by the forming half-apex angle θ. The ironing ratio ψt varies with θ. The ironing ratio ψt is smaller when is larger.
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Ambrogio, Giuseppina, Luigino Filice, and Francesco Gagliardi. "Enhancing Incremental Sheet Forming Performance Using High Speed." Key Engineering Materials 473 (March 2011): 847–52. http://dx.doi.org/10.4028/www.scientific.net/kem.473.847.
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Flexible sheet metal forming processes represent one of the most relevant industrial issues of the scientific research. Incremental Sheet Forming is one of the most promising answers for many production scenarios. In particular, it becomes competitive when the production lot size decreases and the production variability increases. The process is basically set up on numerically controlled machines: a blank is clamped at its border and progressively deformed by a punch that moves according to a proper tool path program, reproducing the final part shape. Thus, the manufacturing time is directly dependent on the tool path length. Up to now, this aspect is one of the reasons why a systematic industrial application is not permitted. To overcome this drawback, an experimental investigation was planned in order to evaluate how the process is affected changing the cycle time. More in detail, an extended experimental investigation on the influence of process speed (i.e. tool rotation speed, tool feed) and other process parameters was executed taking into account a relatively simple 3D component. An accurate analysis of the obtained parts was performed, with particular attention to the thinning distribution that, of course, influences the material failure. Finally, the surface quality was also measured as an output variable.
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Kopac, J., and Z. Kampus. "Incremental sheet metal forming on CNC milling machine-tool." Journal of Materials Processing Technology 162-163 (May 2005): 622–28. http://dx.doi.org/10.1016/j.jmatprotec.2005.02.160.
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Rauch, Matthieu, Jean-Yves Hascoet, Jean-Christophe Hamann, and Yannick Plenel. "Tool path programming optimization for incremental sheet forming applications." Computer-Aided Design 41, no. 12 (December 2009): 877–85. http://dx.doi.org/10.1016/j.cad.2009.06.006.
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Bârsan, A., M. O. Popp, G. P. Rusu, and A. I. Maroșan. "Robot-based incremental sheet forming – the tool path planning." IOP Conference Series: Materials Science and Engineering 1009 (January 16, 2021): 012004. http://dx.doi.org/10.1088/1757-899x/1009/1/012004.
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Liu, Jie. "FEM Analysis of Sheet Incremental Forming Process." Applied Mechanics and Materials 571-572 (June 2014): 1079–82. http://dx.doi.org/10.4028/www.scientific.net/amm.571-572.1079.
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Sheet incremental forming is a new sheet metal dieless forming technology. This paper introduced the fundamentals of the sheet incremental forming process. Based on the principle of “layered manufacture” in rapid prototype technology, this process resolves the intricate three-dimensional geometry information of the workpiece into a series of two-dimensional data, which can be used by an NC system to control a forming tool to make a curvilinear movement over the raw sheet metal layer by layer until the component wanted is formed. This paper introduced the sheet incremental forming system and metal digital forming technology. An FEM model of the incremental forming process is established, and a typical process is analyzed to instruct the parameters selection and the optimization of the forming tracks.
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Otsu, Masaaki, Yosuke Katayama, and Takayuki Muranaka. "Effect of Difference of Tool Rotation Direction on Forming Limit in Friction Stir Incremental Forming." Key Engineering Materials 622-623 (September 2014): 390–97. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.390.
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An effect of tool rotation direction on forming limit in friction stir incremental forming was studied. A 3-axes NC milling machine and a hemispherical tool which with a diameter of 6 mm made of high speed steel was used for forming. The thickness of commercial A5052-H34 aluminum sheet was 0.5 mm. The forming tool was moved from the outside to inside in a pitch of 0.5 mm spirally, and the sheets were formed into frustum of pyramid shape. Formability evaluated by minimum wall angle of the pyramid was investigated by changing a tool rotation rate, tool feed rate and tool path direction. When the tool paths were clockwise and counter clockwise, they were defined to “advancing direction” and “retreating direction” as well as in friction stir welding, respectively. From the experimental results, forming limits by both rotation directions of advancing and retreating were almost the same, however, the range of formable working conditions in advancing direction was slightly wider than that in retreating direction. Evaluating the forming limits in relative velocity between the tool surface and the sheet, no difference of forming limit was obtained between forming in advancing direction and retreating directions.
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Zhou, Liu Ru. "Study on Mechanism of NC Sheet Metal Incremental Forming." Advanced Materials Research 239-242 (May 2011): 940–43. http://dx.doi.org/10.4028/www.scientific.net/amr.239-242.940.
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The principle of NC incremental sheet metal forming process as well as the experiment of cone forming are presented. Because the deformation of sheet metal only occurs around the tool head and the deformed region is subjected to stretch deformation, the deformed region of sheet metal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheet metal deformation. The experiment results show that in the case of the parallel line type tool path, a uniform thickness of the deformed region is maintained and in good accordance with that obtained by the sine law. It is found that success in the forming depends on the forming half-apex angleθof the truncated cone. It can be obtained that NC incremental sheet metal forming process is a plane deform process and conforms to the sine law, i.e.t=t0 sinQ.
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Karbowski, Krzysztof. "Application of Incremental Sheet Forming." Management and Production Engineering Review 6, no. 4 (December 1, 2015): 55–59. http://dx.doi.org/10.1515/mper-2015-0036.
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Abstract This paper describes some manufacturing aspects and an example of application of the Incremental Sheet Forming (ISF) technology which was used for production of the craniofacial prosthesis. The brief description of prosthesis designing was presented as well. The main topic of the paper is comparison of milling and ISF technologies for preparing the tools for prosthesis thermoforming.
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Wu, S. H., Ana Reis, F. M. Andrade Pires, Abel D. Santos, and A. Barata da Rocha. "Study of Tool Trajectory in Incremental Forming." Advanced Materials Research 472-475 (February 2012): 1586–91. http://dx.doi.org/10.4028/www.scientific.net/amr.472-475.1586.
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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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Dien, Le Khanh, Nguyen Van Thanh, and Nguyen Tan Hung. "A research on a new structure of forming tool in Single Point Incremental Forming (SPIF)." Science & Technology Development Journal - Engineering and Technology 3, SI1 (August 17, 2020): SI157—SI163. http://dx.doi.org/10.32508/stdjet.v3isi1.757.
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Single Point Incremental Forming (SPIF) is really a new technology of forming metal sheet nowadays and in recent decades. Although it was invented in, 1967 by Lezak, an American inventor, but the applications of the innovative technology were broad from 1990 because of the advance of controlling technology. This technology is especially adapted to small batch, unique or single productions. There are many forming parameters that influence to the formability of the metal sheet workpiece such as diameter of tool, the revolution per minute of the tool tip, the vertical feed rate after each orbit, the velocity of tool in horizontal plane…. Among of them, in our own experiences, we recognize that in almost all cases, the revolution per minute of the forming tool when forming ferric material sheet such as mild steel, stainless steel, hard steels… should be as small as possible to get the biggest ability of deformation of the workpiece sheet to get rid of failure on the lateral edge of the sheet. The tangential velocity of forming point on the spherical tool tip should be selected to attain the situation of rolling but no sliding of the surface of the spherical tool on the one of the sheet material. The paper recommends a new version of a forming tool in which the tip of the tool is a very hard ball (such as the quenched ball in a ball bearing) that is freely rotate by the friction to modify the contact point on the spherical surface of the tool to avoid the abrading and keep the spherical shape and the situation of rotating but no sliding on the surface of the workpiece sheet as mentioned above. The manufacture of the innovative forming tool is performed and then empirical processes verified it. The models formed by the typical tool are better in comparison with the ones of normal forming tool.
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Allwood, J. M., D. R. Shouler, and A. Erman Tekkaya. "The Increased Forming Limits of Incremental Sheet Forming Processes." Key Engineering Materials 344 (July 2007): 621–28. http://dx.doi.org/10.4028/www.scientific.net/kem.344.621.
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Incremental sheet forming is known to give higher forming limits than conventional sheet forming processes, but investigation of this effect has been impeded by the computational cost of process models which include detailed predictions of through thickness behaviour. Here, a simplified process is used to gain insight into the mechanics of a broad class of incremental forming processes. The simplified process is described and shown to give increases in forming limits compared to a conventional process with the same geometry. A model of the process is set up with a commercial finite element package, validated, and used to trace the history of a ‘pin’ inserted perpendicularly into the workpiece. The history of the deformation of the ‘pin’ demonstrates significant through thickness shear occurring in the direction parallel to tool motion. This insight is used to modify an existing analysis used to predict forming limit curves. The analysis shows that for a sheet with uniform proportional loading, the forming limit is increased when through thickness shear is present, and this is proposed as an explanation for the increased forming limits of incremental sheet forming processes.
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Obaid, Ahmed M., Jumaa S. Chiad, and Ghanim Sh Sadiq. "Incremental Forming of AA8006 Aluminum Alloys Sheet with Different Step Size." Materials Science Forum 1039 (July 20, 2021): 137–43. http://dx.doi.org/10.4028/www.scientific.net/msf.1039.137.
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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.
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Skjoedt, M., M. H. Hancock, and N. Bay. "Creating Helical Tool Paths for Single Point Incremental Forming." Key Engineering Materials 344 (July 2007): 583–90. http://dx.doi.org/10.4028/www.scientific.net/kem.344.583.
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Single point incremental forming (SPIF) is a relatively new sheet forming process. A sheet is clamped in a rig and formed incrementally using a rotating single point tool in the form of a rod with a spherical end. The process is often performed on a CNC milling machine and the tool movement is programed using CAM software intended for surface milling. Often the function called profile milling or contour milling is applied. Using this milling function the tool only has a continuous feed rate in two directions X and Y, which is the plane of the undeformed sheet. The feed in the vertical Z direction is done in the same angular position in the XY plane along a line down the side of the work piece. This causes a scarring of the side and also results in a peak in the axial force when the tool is moved down. The present paper offers a solution to this problem. A dedicated program uses the coordinates from the profile milling code and converts them into a helical tool path with continuous feed in all three directions. Using the helical tool path the scarring is removed, the part is otherwise unchanged and a major disadvantage of using milling software for SPIF is removed. The solution is demonstrated by SPIF of three different geometries: a pyramid, a cone and a complex part.
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Giardini, Claudio, Elisabetta Ceretti, and Aldo Attanasio. "Further Experimental Investigations and FEM Model Development in Sheet Incremental Forming." Advanced Materials Research 6-8 (May 2005): 501–8. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.501.
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Sheet Incremental Forming (SIF) is a modern technique that deforms the sheet on a positive or negative die using a simple punch mounted on a general purpose CNC machine. Several working parameters (tool path, spiral width and tool depth) have been studied in previous papers [1, 2] analyzing their influence on a simple part when working AISI 304 or Cu DHP sheets. The main problem was to study the process feasibility, that is, the possibility of correctly deforming the pieces without breaking them. The research reported here has been focused mainly on other two important variables, studying their influence on the final part quality: the punch diameter and its velocity when deforming the sheet. Surface roughness and minimum thickness of the deformed sheet have been chosen as parameters for analyzing and evaluating the process efficiency. In FEM analysis, a simulation model was developed and implemented considering Cu DHP sheet. The comparison with experimental results was used to validate the simulation model and to identify the most suitable simulation parameter values (friction coefficient between various elements and blank holder force). The developed and validated model can be used for studying the process optimization. The results obtained in this paper can also be used as guidelines for the correct design of Sheet Incremental Forming process.
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Lu, Bin, Dong Kai Xu, Run Zhe Liu, Heng An Ou, Hui Long, and Jun Chen. "Cranial Reconstruction Using Double Side Incremental Forming." Key Engineering Materials 639 (March 2015): 535–42. http://dx.doi.org/10.4028/www.scientific.net/kem.639.535.
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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.
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Kumar, Gautam, and Kuntal Maji. "Formability of AA7075 Sheet in Single Point Incremental Forming." International Journal of Manufacturing, Materials, and Mechanical Engineering 11, no. 2 (April 2021): 40–54. http://dx.doi.org/10.4018/ijmmme.2021040103.
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This article presents formability analysis of aluminium alloy 7075 thin sheets in single point incremental forming (SPIF) through prediction of forming limit curve (FLC) and maximum formable wall angle. Deformation instability method based on tool-sheet contact and non-contact zones in incremental forming was used for the prediction of limit strains for plane strain and equi-biaxial stretching strain path. FLC of the material was also determined experimentally, after measuring limit strains for deformed sheet through groove test for the process. Further, maximum forming wall angle of the material was determined for deformed sheet in a square pyramid shape. The theoretical limit strains predicted by deformation instability approach were compared to the experimental values. Theoretically, calculated limit strains were observed to be higher for plane strain path but approximately close for equi-biaxial strain path compared to experimental limit strains. The maximum formable wall was found to be 55˚ for the material in the process.
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Jung, Kyu-Seok, Jae-Hyeong Yu, Wan-Jin Chung, and Chang-Whan Lee. "Tool Path Design of the Counter Single Point Incremental Forming Process to Decrease Shape Error." Materials 13, no. 21 (October 22, 2020): 4719. http://dx.doi.org/10.3390/ma13214719.
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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.
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Langstädtler, Lasse, Holger Pegel, Marius Herrmann, Christian Schenck, and Bernd Kuhfuss. "Electrohydraulic incremental bulk metal forming." MATEC Web of Conferences 190 (2018): 03001. http://dx.doi.org/10.1051/matecconf/201819003001.
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Electrohydraulic forming is a working media based high speed technique that is usually applied for sheet metal processing. In this process a shock wave acts as a flexible punch that transmits the punching force in a very short period of time. This force is usually used to accelerate the workpiece towards the passive tool. In Contrast to sheet forming, the electrohydraulic method is still not adapted to bulk forming. Although, the exchange of a mechanical rigid punch by a shockwave with a flexible shape enables special advantages especially if parts with millimeter dimensions or smaller are to be processed. But in case of deep and small cavities with a high aspect ratio are to be filled, the forming energy is not transferable within one shock wave. To overcome these obstacles the incremental electrohydraulic forming is introduced. As an example, the electrohydraulic extrusion of cylindrical samples (aluminum Al99.5) with an initial diameter of 1.5 mm was performed with a series of consecutive shock waves.
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Riaz, Asim Ahmad, Naveed Ullah, Ghulam Hussain, Mohammed Alkahtani, Muhammad Naeem Khan, and Shaukat Khan. "Experimental Investigations on the Effects of Rotational Speed on Temperature and Microstructure Variations in Incremental Forming of T6- Tempered and Annealed AA2219 Aerospace Alloy." Metals 10, no. 6 (June 17, 2020): 809. http://dx.doi.org/10.3390/met10060809.
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This research work primarily focused on investigating the effects of changing rotational speed on the forming temperature and microstructure during incremental sheet metal forming (ISF) of AA-2219-O and AA-2219-T6 sheets. Tool rotational speed was varied in the defined range (50–3000 rpm). The tool feed rate of 3000 mm/min and step size of 0.3 mm with spiral tool path were kept fixed in the tests. The sheets were formed into pyramid shapes of 45° draw angle, with the hemispherical end forming tool of 12 mm diameter. While the sheets were forming, the temperature variation due to friction at the sheet–tool contact zone was recorded, using a non-contact laser projected infrared temperature sensor. It was observed that the temperature rising rate for the T6 sheet during ISF is higher as compared to the annealed sheet, thereby showing that the T6 tempered sheet offers higher friction than the annealed sheet. Due to this reason, the T6 tempered sheet fails to achieve the defined forming depth of 25 mm when the rotational speed exceeds 2000 rpm. The effects of rotational speed and associated rise in the temperature were examined on the microstructure, using the scanning electron microscopic (SEM). The results reveal that the density of second phase particles reduces with increasing speed reasoning to corresponding temperature rise. However, the particle size in both tempers of AA2219 received a slight change and showed a trivial response to an increase in the rotational speed.
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Zhu, Hu, Nan Li, and Jin Ju. "Research on the Simulation for Sheet Metal NC Incremental Forming." Applied Mechanics and Materials 441 (December 2013): 498–501. http://dx.doi.org/10.4028/www.scientific.net/amm.441.498.
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In the sheet metal CNC incremental forming, the forming is realized by its tool's step by step and point by point extrusion movements along the pre-programmed contour tool path in the outline of the sheet part. Therefore, the correctness of the forming path used to control the tool's movement has a magnificent impact on the forming quality. And a NC incremental forming process simulation method which is used to verify the correctness is showed in this paper. Meanwhile the simulation software system is developed by using VC++ and OpenGL. The case study shows that the software system can be used in the verification of NC incremental forming path and the motion analysis of forming tool, and the software system runs steadily and reliably.
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Wu, Jin Han, and Qiu Cheng Wang. "Comparison of the Geometric Accuracy by DSIF Toolpath with SPIF Toolpath." Applied Mechanics and Materials 494-495 (February 2014): 497–501. http://dx.doi.org/10.4028/www.scientific.net/amm.494-495.497.
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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.
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Liu, Jie. "A New Incremental Sheet Forming Process Based on Layer Manufacture." Applied Mechanics and Materials 607 (July 2014): 124–27. http://dx.doi.org/10.4028/www.scientific.net/amm.607.124.
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Sheet dieless digital forming is a new sheet metal dieless forming technology. This paper introduced the fundamentals of the Sheet dieless digital forming process. Based on the principle of “layered manufacture” in rapid prototype technology, this process resolves the intricate three-dimensional geometry information of the workpiece into a series of two-dimensional data, which can be used by an NC system to control a forming tool to make a curvilinear movement over the raw sheet metal layer by layer until the component wanted is formed. This paper introduced the Sheet dieless digital forming system and metal digital forming technology.