Numerical Study of a Variable Wall Angle Made of DC01 Steel by Incremental Forming Process (original) (raw)
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Experimental and Finite Element Analysis of Single Stage Single Point Incremental Forming
International Journal of Engineering, 2021
Incremental forming is one of the non-traditional forming processes which is widely used in rapid prototyping and customized component manufacturing. One of the challenges encountered in single stage single point incremental forming (SSSPIF) is difficulty in achieving greater wall angle for a considerable depth. In this research work, the investigation is carried out by experimental and numerical simulation for reaching the maximum wall angle to a possible depth without any defects in SSSPIF. SSSPIF of truncated cone shaped component from 1mm thick AISI304 austenitic stainless steel are made at a different wall angles. Also, numerical simulation using LS-DYNA explicit solver is performed and the results are validated with the experimental values. Components with the wall angle of 64o is successfully made without any defects made in a single stage forming for a depth of 45 mm within the experimented process parameters. Major strain, minor strain and thickness distribution in the sheet material due to forming process are obtianed from experiments and finite element analysis (FEA). From the results of both experiment and FEA, it is observed that the major strain, minor strain and thinning effects are higher in the region below the major diameter of the truncated cone at all experimented wall angles. Also the FEA results have shown good agreement with the experimental values. Further it is seen that the strains are increasing with the increase of wall angle.
Periodica Polytechnica Mechanical Engineering
Incremental sheet forming (ISF) is an innovative cold forming operation and has enticed great interests owing to its flexibility and capability to manufacture various complex 3D shapes with low costs and minimum requirements. Single point incremental forming (SPIF) is the most popular type of ISF process and has high quality and less occurrence of defects for the formed products if the operating parameters are achieved and evaluated with high precision. In this study, the impact of tool diameter and forming angle on the forming force, thickness distribution, thinning ratio, effective plastic strain, forming depth and fracture behaviour was explored. AA1050 aluminium alloy and DC04 carbon steel were employed to produce a truncated cone in accordance with the SPIF process. A 3D finite element model was required to achieve a well-established investigation. The SPIF of a truncated cone numerical model was adopted to build a model with the same conditions as of the experimental work with...
INVESTIGATION ON SINGLE POINT INCREMENTAL FORMING PROCESS CONSIDERING VARIOUS TOOL PATH DEFINITIONS
Transstellar Journal , 2019
Single point incremental forming (SPIF) has a great contribution in industrial practice, because the desired parts such as the small-batch production and prototype products can be manufactured just by changing the punch tools and supports. The sheet is formed into desired part using punch tools by producing local plastic deformations at the contact locations based on designed tool paths. This research work is aimed to investigate the formability of SPIF process over the numerical simulations in terms of various geometries and tool paths with varied constant depth, tool radius and feed rate test conditions. The mechanical properties of an aluminum alloy were considered and incorporated into the finite element (FE) code and further, the procedure to perform the forming process was modeled in LS-DYNA tool. To reduce computational time and eliminate the inconsistent results, the symmetry boundary conditions for symmetrical shapes were exploited and discussed. Thereafter, results achieved from the numerical simulations were compared with the desired part to make sure that the suitable FE model was developed. Discussion on the thickness distributions in terms of thinning area, thinning location and its size in percentage are presented. The thickness reduction in both geometries indicates that thinning occurs uniformly in the wall region and small fluctuation noticed near the tool retraction location. In detail, a bending region was observed with continuous thickness reduction and the desired geometry was accomplished from the base plate configuration by controlling the stretching deformation at the start of forming process.
Numerical-Experimental Study Regarding the Single Point Incremental Forming Process
MATEC Web of Conferences
The present paper proposes a numerical-experimental comparative study on the single point incremental forming process. A DC04 steel sheet with a thickness of 0.6 mm was used for both the numerical simulation using the finite element method and the experimental research. The type of trajectory used was a spiral trajectory and the finished part obtained was a truncated cone-shaped part. The analysis program used for simulation was Ls-Dyna. The simulations were performed in several variants: with a fixed mesh and with an adaptive mesh, using two different element formulations: 25 (Belytschko-Tsay formulation with thickness stretch) and -16 (fully integrated shell element modified for higher accuracy) and two contact types: automatic surface to surface (ASTS) and forming one way surface to surface (FOSS). The results of the numerical analysis and of the experimental research were focused on determining the major strain, minor strain, thickness reduction and forces at the end of the sing...
Advances in Science and Technology Research Journal
Single-point incremental forming (SPIF) is a kind of incremental sheet forming that is significantly novel. This method involves the utilization of a computer numerical control (CNC) machine to control the path of a forming tool, which is produced by a computer-aided manufacturing program (CAM), as it stretches a metallic sheet to achieve a desired shape. Low patch output and customized parts are good candidates for this kind of technique. The aim of the present investigation is first to study the effect of Aluminum alloy 6061 strength on the thickness distribution and thinning ratio in SPIF and then select the optimal strength to ensure uniform thickness and minimize the thinning. In order to achieve this, two different strengths of Al 6061 sheets have been employed: One used in its original form and the other heat treated to change its strength. Specimens have been prepared using the SPIF procedure for a truncated cone with dimensions of 120 mm diameter and 40 mm depth; the forming slope is 50°, and Solid work program was used to create the tool path. The thickness reduction along the wall portions was analyzed employing the finite element method using Abaqus software, and the numerical results were experimentally confirmed, where the deviation ratio between simulation and experiment was 3% for sample 1 and 5% for sample 2. The findings manifested that the specimens exhibited a consistent distribution of thickness, and the maximum thinning ratio decreased from 30% to 28.5% as the yield strength decreased from 278 MPa to 68.7 MPa, respectively.
In single point incremental forming (SPIF) process, the blank is formed in a stepwise approach by a displacement-controlled round nose tool. Due to specific strain paths induced by the process and limited plastic zones in the contact region between the tool and the workpiece, the formability limit diagrams are different from the traditional deep drawing process. In this paper, the SPIF process is numerically exercised and experimentally validated with grid-based deformation process. Development of strain fields encountered in incremental forming is reported and material formability of AA2024-O is evaluated on conical formed shapes.
Numerical And Experimental Studies On Single Point Incremental Forming Of Rotational Parts
New methods of forming sheet metal are now at a stage where it is possible to make either custom manufactured parts or to manufacture small batch production quantities, with very short turnaround times from design to manufacture. Current developments have been focused on forming asymmetric parts using CNC technology, without the need for costly dies. Single Point Incremental Sheet Forming has the potential to revolutionize sheet metal forming, making it accessible to all levels of manufacturing. In this work FEA of incremental sheet metal forming is carried out using ABAQUS/Explicit to optimize process parameters. Theoretical forming limit diagrams were constructed using Levy-Mises flow rule for plastic deformation. L9 model with 9 experimental runs were selected using design of experiment by Taguchi method using for 3-factors 3-levels design. Three process parameters considered were diameter, vertical step size and feed rate. Optimization is done for maximum fracture depth and percent contribution of each process parameter on response is calculated by ANAOVA statistical models. Rotational parts i.e. frustum of cone was formed by incremental method using CNC VMC. Result includes measurement of thickness and strain distribution and construction forming limit diagram. Strain measurement on formed component was done using circle grid analysis. FLDs constructed using experimental data were compared with the theoretical FLDs.
Al-Khwarizmi Engineering Journal, 2018
Incremental sheet metal forming process is an advanced flexible manufacturing process to produce various 3D products without using dedicated tool as in conventional metal forming. There are a lot of process parameters that have effect on this process, studying the effect of some parameters on the strain distributions of the product over the length of deformation is the aim of this study. In order to achieve this goal, three factors (tool forming shape, feed rate and incremental step size) are examined depending on three levels on the strain distributions over the wall of the product. Strain measurement was accomplished by using image processing technique using MATALB program. The significance of the control factors are explored using two statistical methods: analysis of variance (ANOVA) and main effect plot (MEP). All experiments were carried out on a sheet of Aluminum alloy (Al1050) with thickness 0.9 mm by using 3 axes CNC machine to produce frustum pyramid product. The result showed that the feed rate is a parameter that has large effect on the values of the effective strain percentage contribution of (42.86% and 51.42%), respectively, and is followed by step size (25.1% and 30.60%) percentage contributions and finally the tool shape with (21.79% and 10.54%) on the (55° and 45°) wall angle, respectively. The maximum and minimum average effective strain computed on the 55◦ forming angle were (0.580 and 0.399), respectively. Finally, the maximum and minimum average effective strain computed on the 45◦ forming angle were equal to (0.412 and 0.324), repectively
An FEM-aided investigation of the deformation during Single Point Incremental Forming
Incremental forming is an innovative and flexible sheet metal forming technology for small batch production and prototyping, which does not require any dedicated die or punch to form a complex shape. This paper investigates the process of single point incremental forming of an aluminium cone both experimentally and numerically. Finite element models are established to simulate the process. The output of the simulation is given in terms of final geometry, the thickness profile of the product and the strain history and distribution during the deformation. Comparison between the simulation results and the experimental data is made.
Experimentation and FE simulation of single point incremental forming
Materials Today: Proceedings, 2019
One of the emerging flexible forming technologies in the sheet metal engineering is the incremental sheet forming, it uses universal tooling that is mostly part independent. Hence this process provide higher flexibility reducing the product development greatly and making it useful for low volume production. Single Point Incremental forming is drawing attention of the researchers & scientist all over the world because of the attractive characteristics. Like: improved formability, elimination of die & conventional press and ease of operation on general purpose Vertical Machining Centre. As this way of creating sheet metal formed products is in development stage, the factors affecting this needs comprehensive investigations. In this paper experimental and numerical investigation of formability of Aluminium 8011 alloy are presented and compared by preparing a conical frustum shape using SPIF process. The complete process is simulated using CATIA manufacturing simulation model to generate the path of Hemispherical end tool tip. Numeric Control (NC) part program is generated with the help of this simulated path to form the sheet into conical frustum shape on CNC mill machine. Four process parameters viz. vertical step depth, feed rate, spindle speed and angle of cone are chosen for the experimental investigations keeping height of the cone and material sheet thickness constant. Temperature, thickness reduction, strain and machining time are selected as a response variable. Optimizations are performed using TAGUCHI and ANOVA while the numerical study of the process is performed through ANSYS workbench software to predict stress, strain, temperature and thickness Results of experiments and numerical study are in close accord.