Incremental sheet forming (ISF) is a relatively new flexible forming process. ISF has excellent adaptability to conventional milling machines and requires minimum use of complex tooling, dies and forming press, which makes the process cost-effective and easy to automate for various applications. In the past two decades, extensive research on ISF has resulted in significant advances being made in fundamental understanding and development of new processing and tooling solutions. However, ISF has yet to be fully implemented to mainstream high-value manufacturing industries due to a number of technical challenges, all of which are directly related to ISF process parameters. This paper aims to provide a detailed review of the current state-of-the-art of ISF processes in terms of its technological capabilities and specific limitations with discussions on the ISF process parameters and their effects on ISF processes. Particular attention is given to the ISF process parameters on the formability, deformation and failure mechanics, springback and accuracy and surface roughness. This leads to a number of recommendations that are considered essential for future research effort.

/pdf/review-on-the-influence-of-process-parameters-in-incremental-1pn9zyph0o.pdf

Review on the influence of process parameters in incremental sheet forming

Feature-based tool path generation approach for incremental sheet forming process

This paper presents a detailed literature review on the current research of incremental sheet forming relating to deformation mechanism, modelling techniques, forming force prediction and process investigations. First, a review of the fundamental deformation mechanism and formability in incremental sheet forming (ISF) is provided. Subsequently, the modelling techniques for ISF are reviewed and categorised into two approaches: analytical modelling and finite element modelling. Special interest is given to a critical review regarding the forming forces analysis and prediction during the process. Then, previous publications related to geometric accuracy, surface finish and forming efficiency in ISF are reviewed. Finally, several potential hybrid incremental sheet-forming strategies are discussed. This leads to a statement of conclusion which may act as an inspiration and reference for the researcher.

A review on the recent development of incremental sheet-forming process

Tool path optimization for single point incremental sheet forming using response surface method

Closed-loop feedback control of product properties in flexible metal forming processes with mobile tools

Asymmetric two points incremental forming: Improving surface quality and geometric accuracy by tool path optimization

Sheet Incremental Forming (IF) is a forming technology which consists of a sheet clamped along its edges by a suitable blank-holder while an hemispherical head punch is moved along a defined path and locally deforms the sheet. To improve the part geometrical accuracy, a die (which can be positive or negative) is placed behind the sheet with respect to the punch position. In this case, the process is called Two Point Incremental Forming (TPIF). In the present paper TPIF with positive die was studied through an experimental tests campaign using deep drawing steel sheets. The die geometry used in this research was chosen so to be representative of the process and it was tested using different tool paths. Forming forces were measured using self designed instrumented punch and table while the final workpiece geometry was detected using a coordinate measuring machine (CMM). The collected data allowed to study the effects of the different tool paths on the maximum forming forces, the geometry errors, the maximum reachable wall angle and the drawing depth during forming and after springback. The results were also compared with a previously performed experimental campaign where similar tests with negative die were conducted.

Analysis of forces, accuracy and formability in positive die sheet incremental forming

The welding mechanism is one of the most important topics when studying porthole die extrusion. The present paper describes the implementation of the criterion proposed by Plata and Piwnik in DEFORM 2D environment. The innovative aspect is that it is possible to actually “weld” the material instead of studying only the self-contact of the material. In this way complete information on how the material welds are obtained and the evolution of the weld parameter during the entire process is plotted. This procedure was used to evaluate the influence of die geometrical parameters on the welding formation. The results show that the implemented methodology is capable to monitor the welding evolution during the extrusion process, and can be used to predict the influence of process parameters on the welding formation and part quality evaluation.

Simulation of metal flow and welding prediction in porthole die extrusion: the influence of the geometrical parameters

Design of an equipment for forces measurement in tpif process

The aim of this work is to design and to improve the geometry of a porthole‐die for the production of aluminum components by means of 3D FEM simulations. In fact, the use of finite element models will allow to investigate the effects of the die geometry (webs, extrusion cavity) on the material flow and on the stresses acting on the die so to reduce the die wear and to improve the tool life. The software used to perform the simulations was a commercial FEM code, Deform 3D. The technological data introduced in the FE model have been furnished by METRA S.p.A. Company, partner in this research. The results obtained have been considered valid and helpful by the Company for building a new optimized extrusion porthole‐die.

Luca Mazzoni

Papers

Asymmetric two points incremental forming: Improving surface quality and geometric accuracy by tool path optimization

Analysis of forces, accuracy and formability in positive die sheet incremental forming

Simulation of metal flow and welding prediction in porthole die extrusion: the influence of the geometrical parameters

Design of an equipment for forces measurement in tpif process

3D FEM Geometry and Material Flow Optimization of Porthole‐Die Extrusion