Fundamental studies on the incremental sheet metal forming technique (original) (raw)
Related papers
Analysis of the metal sheets formability at single point incremental forming process
MATEC Web of Conferences
Although research on incremental forming process began a few decades ago, it is still a process in development phase. Single point incremental forming is a simple process and the deformation of the sheet blank is done with the help of a punch that follows a known toolpath. In the case of this process, one important aspect is the prediction of material failure. To achieve this with the help of a finite element analysis, a series of experiments were performed to determine the forming limit diagram. In this paper, an attempt has been made to determine the forming limit diagram for the AA1050 aluminum alloy. The experiments were performed with the help of an industrial robot, KUKA KR 210-2, thus the part can be measured with an optical measuring instrument obtaining the major and minor strain from forming limit diagram.
Improvement of formability for the incremental sheet metal forming process
International Journal of Mechanical Sciences, 2000
In order to obtain competitiveness in the "eld of industrial manufacture, a reduction in the development period for the small batch manufacture of products is required. In order to meet these requirements, an incremental sheet metal forming process has been developed. In this process, a small local region of a sheet blank deforms incrementally by moving a hemispherical head tool over an arbitrary surface. In this work, an incremental sheet metal forming process controlled three dimensionally by a computer has been accomplished. It has been shown by the experiments that a sheet blank is mainly subject to shear-dominant deformation. Therefore, the "nal thickness strain can be predicted. The uniformity of thickness throughout the deformed region is one of the key factors to improve the formability in the sheet metal forming processes. Using the predicted thickness strain distribution, the intermediate geometry is decided in the manner that a shear deformation is restrained in the highly shear-deformed region and vice versa. This double-pass forming method is found to be very e!ective so that the thickness strain distribution of a "nal shape can be made more uniform.
Experimental Investigation of Thickness Distribution in Incremental Sheet Forming for Aluminium
—Incremental Sheet Forming (ISF) is gaining a lot of attention due to the ease with which it forms metal sheets to required shape and the capability of the process to form custom made products economically. The material used for the experimentation is Aluminium sheet AA1100 grade. This alloy is commercially pure aluminium with excellent forming characteristics. In this paper effect of four parameters namely Tool size, Spindle speed, Step size and Wall inclination on thickness distribution in ISF process is discussed. The results show that formability in ISF is highly variable with input parameters. It was found that the thickness in mid region of forming depth is less than the thickness at the corners. Further it was evident from results that wall inclination below 20° is not possible with single pass forming in ISF.
Parametric Review of Incremental Sheet Forming Process for Various Applications
mantech publications, 2023
Incremental sheet forming is an advanced and efficient technique for performing forming operations when complex forming shapes or mass production for formed products is taken into consideration. ISF is widespread due to its flexibility in experiments and economically it is much more preferable. Unlike traditional forming methods tool in ISF is controlled numerically by CNC machines and therefore is preferred by great many industries for its applications in forming. For example, light weight alloys are used hugely in automobile industry, so it needs fast and cost efficient process to design and manufacture complex shapes like door frames and bumpers with great geometrical accuracy and good surface quality. This work presents various researches regarding experiments performed in ISF with different areas of focus such as tool geometry, sheet metal thickness, surface finish, sheet material etc. Tool geometry plays a vital role in ISF process when it comes to unusual and complex shapes and hence more and more optimization is in dire need for today's researchers. Therefore, this literature review would offer a clear idea as to how much success is achieved in ISF and how much work is yet to be done regarding optimization of tool geometries in Incremental Sheet Forming process.
Study of Accuracy in Incremental Sheet Forming Of Aluminium
– The Incremental Sheet Forming process is quickly developed as it is capable of delivering custom made parts or batch products economically as per the market needs. In this process the tool imparts local plastic deformation on sheet and tool movement along the sheet forms it into the required shape. In present study the accuracy of the single pass incremental sheet forming is tested experimentally on a commercial grade aluminium alloy. It was found that 20° wall inclination is not possible to form with the single pass forming. The results show that the single pass incremental sheet forming is not much accurate as there was differences between theoretical and measured diameters of sheet.
A review of various Parameters of Incremental Sheet Forming Process and their effects
IRJET, 2022
ISF (Incremental Sheet Forming) is a new metal forming technique which does not have the punch and die & achieves better dimensional accuracy. This technology is especially helpful for small and medium-sized batch manufacturing and prototyping since it is less expensive than traditional sheet metal forming procedures. Design adjustments can be made fast and easily because it can be done on a standard CNC machine. The components can be manufactured straight from the CAD file. One of the biggest advantages of Incremental Sheet Forming process is the strain hardening effect involved during plastic deformation of product can be minimized. To ensure the applicability of ISF, guidelines describing the relationship between input parameters and process formability are required.. The paper includes the review of various researchers on how the parameters like tool diameter, step size, thickness, forming angle, wall angle, temperature, spindle speed etc. The effects of post process parameters like roughness & spring back are also mentioned based on the results of various researchers.
A Review of Fundamentals and Advancement in Incremental Sheet Metal forming
2013
ISF (incremental sheet metal forming) is a technique which uses CNC tools to form sheet metals. The method is not applicable for mass production but found to be very useful in small batch quality production. The study includes fundamentals of incremental sheet metal forming, classifications, tools used and effect of various parameters such as plane anisotropy, tool size and shape, lubrication on it. The study also includes the advance methods incorporated in ISF such as doubly curved surfaces, Hybrid forming etc, their advantages and limitations.
Effects of various Parameters while forming using Incremental Sheet Forming Process
Incremental Sheet Forming (ISF) is an emerging metal forming technology which does not have the punch and die & achieves better dimensional accuracy. This process is particularly useful for the production and prototyping of small & medium sized batches as it incorporates lower cost compared to the conventional sheet metal forming processes. As it can be executed in a conventional CNC machine, design changes can be quickly and easily carried out. The parts can be produced directly from the CAD file. One of the biggest advantages of Incremental Sheet Forming process is the strain hardening effect involved during plastic deformation of product can be minimized. Guidelines regarding the relation between input parameters & the formability of the process are required for assuring the applicability of ISF. The paper includes the review of various researchers on how the parameters like tool diameter, step size, thickness, forming angle, wall angle, temperature, spindle speed etc. The effects of post process parameters like roughness & spring back are also mentioned based on the results of various researchers.
A comparative study on the forming limits of an aluminum sheet-metal in negative incremental forming
Journal of Materials Processing Technology, 2007
The paper presents a comparison of the forming limits of an aluminum sheet-metal tested by forming two categories of the parts: (1) the parts whose slope varies along depth and (2) the parts having fixed slope along depth. In order to design the former kind of the parts/surfaces, the curve-segments of various geometrical functions were selected as generatrices, and the mathematical formulation was carried out to predict the formability parametersforming angle limit and thinning limit -of the sheet-metal. The formability parameters from these parts were acquired by forming them until they were fractured, and the results obtained showed that the formability of the sheet-metal depends upon the slope distribution along an axi-symmetric part to be formed. A collection of the latter category of the parts/surfaces was created with a variety of slopes, and the maximum slope/wall angle that the sheet-metal can endure without fracturing was determined. It has been concluded that the formability of the sheet-metal depends upon the slope distribution along the part utilized in the test, and the former category of the parts exhibit higher forming limits than the latter one.
Advances in Materials and Processing Technologies
Incremental forming is a method with great forming potential. With this method, especially Low-Alloy Sheet Metals prototypes can be produced. Low-Alloy Sheet DC01, one of the metals, is widely used in the machinery industry. In this study,manufacturability of conical frustum part with circular generatrix form was investigated by "single point incremental forming" method. DC01 sheet was used as the test material. Signal/Noise analysis was performed to investigate the effects of experimental parameters. Later, gray relationship analysis performed. The optimal parameters for the incremental formability of the variable wall angle conical frustum shaped DC01 sheet metal were determined. As the increment and the feedrate decreased, it was observed that both surface roughness and forming force decreased. Surface roughness and forming force are both observed to increase with the growth of the forming tool diameter.