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Journal ArticleDOI

An experimental study on geometric accuracy in hybrid incremental sheet forming

02 Oct 2021-Advances in Materials and Processing Technologies (Informa UK Limited)-Vol. 7, Iss: 4, pp 684-695
TL;DR: In this paper, influence of process parameters in hybrid incremental sheet forming (HISF) is studied, and stretch forming combined with ISF is used for forming of conical parts.
Abstract: In the present experimental study, influence of process parameters in hybrid incremental sheet forming (HISF) is studied. Stretch forming combined with ISF is used for forming of conical parts. Str...
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Book ChapterDOI
01 Jan 2019
TL;DR: In this paper, the authors used a hemispherical ended forming tool of stainless steel (SS-304) to form frustum of cones with wall angle from 30° to 70°.
Abstract: Poor geometric accuracy of formed parts is one of the key drawbacks in incremental sheet forming (ISF) process. In present experimental study, ISF is combined with stretch forming (SF) to improve the accuracy of formed parts. Influence of process parameters namely preforming, preform tool radius, wall angle, and tool offset on the geometric accuracy of parts formed in ISF process is investigated. A hemispherical ended forming tool of stainless steel (SS-304) is used to form frustum of cones with wall angle from 30° to 70°. Experiments are designed according to Taguchi’s orthogonal array (OA). From the experimental results, it is found that there is considerable influence of wall angle, preforming, and tool offset on the geometric accuracy of formed part. As the wall angle increases, geometric error reduces considerably resulting in accurate part shapes. The results obtained in present study will certainly be helpful to improve geometric accuracy of sheet metal parts formed using ISF in industries.

2 citations

DOI
TL;DR: In this article , the influence of different toolpath methods, approaches, and design of the tool on the geometrical features and surface quality of the fin formed through the bending mode of the DM process was investigated for aluminium alloy Al-6061 T6.
Abstract: ABSTRACT Deformation machining (DM), a hybrid manufacturing process, involves subtractive manufacturing and the incremental forming process. This hybridisation of manufacturing technologies produces monolithic components having complex profiles and reduces raw material wastage. In this work, the influence of different toolpath methods, approaches, and design of the tool on the geometrical features and surface quality of the fin formed through the bending mode of the DM process was investigated for aluminium alloy Al-6061 T6. Different combinations of straight and curved fin toolpath techniques with top-to-bottom and bottom-to-top approaches were investigated to bend the machined fin in the desired shape. Thereafter, different tool profiles were explored with the bottom-to-top approach and curved toolpath strategy. The fabricated fin was 3D scanned to evaluate the geometrical features, and the surface roughness was also measured. The better quality of the formed components in terms of geometrical features and surface roughness was identified with the optimal combination of the tool profile and toolpath strategy, i.e. tool profile T3 has a circular sector and nose radius of 0.5 mm, curved toolpath method, and bottom-to-top approach. This optimal combination was further utilised to analyse the forming forces during the bending mode of the DM process.

2 citations

Journal ArticleDOI
TL;DR: In this paper , the effect of process parameters such as preform tool size, tool diameter, and preforming depth on thinning in the formed part is studied and a simulation model is developed and simulation results are compared with the experimental results.
Abstract: In the present research work, parts are formed using two-step hybrid incremental sheet forming (HISF) process. The effect of process parameters such as preform tool size, tool diameter, and preforming depth on thinning in the formed part is studied. A simulation model is developed and simulation results are compared with the experimental results. Also, results of HISF process are compared with the results of single point incremental sheet forming. The simulation results are in good agreement with the experimental results. It is observed that HISF process results in lower thinning as compared to SPIF process. Further, it is found that preform tool size has considerable influence on the minimum thickness of formed part. Large preform tools result in relatively lower thinning.

1 citations

Journal ArticleDOI
TL;DR: In this article, an experimental investigation of hybrid forming process which combines stretching and single point incremental sheet forming (SPIF) process is done, and the effect of three parameters namely stretching amount, pitch and tool diameter is investigated on response characteristics namely wall thickness and geometric accuracy of formed parts.
References
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Journal ArticleDOI
TL;DR: In this article, a single point incremental forming accuracy suffers from contradictory material requirements: while a low yield strength and low hardening coefficient are favorable in terms of limiting process forces and springback, they also result in excessive, unwanted plastic deformation in zones bordering processed areas.

269 citations

Journal ArticleDOI
TL;DR: In this article, a wide recognition of the research efforts in this field is presented, taking into account some general considerations on the difference sources of shape and dimensional errors, as well as the influence of the most relevant parameters.

228 citations

Journal ArticleDOI
TL;DR: In this article, the authors deal with the optimization of the tool path in two-point sheet incremental forming with full die, in a particular asymmetric sheet incremental form configuration, in order to reproduce an automotive component with the best dimensional accuracy, the best surface quality and the lowest sheet thinning.

153 citations

Journal ArticleDOI
TL;DR: In this article, the authors explored the capabilities of DSIF in terms of improving the geometric accuracy as compared to single point incremental forming by using a novel toolpath strategy in which the sheet is locally squeezed between the two tools.
Abstract: Single point incremental forming (SPIF) is plagued by an unavoidable and unintended bending in the region of the sheet between the current tool position and the fixture. The effect is a deformation of the region of the sheet in between the formed area and the fixture as well as deformation of the already formed portion of the wall, leading to significant geometric inaccuracy in SPIF. Double sided incremental forming (DSIF) uses two tools, one on each side of the sheet to form the sheet into the desired shape. This work explores the capabilities of DSIF in terms of improving the geometric accuracy as compared to SPIF by using a novel toolpath strategy in which the sheet is locally squeezed between the two tools. Experiments and simulations are performed to show that this strategy can improve the geometric accuracy of the component significantly by causing the deformation to be stabilized into a local region around the contact point of the forming tool. At the same time an examination of the forming forces indicates that after a certain amount of deformation by using this strategy a loss of contact occurs between the bottom tool and the sheet. The effects of this loss of contact of the bottom tool on the geometric accuracy and potential strategies, in order to avoid this loss of contact, are also discussed.

101 citations

Journal ArticleDOI
TL;DR: In this paper, a single point incremental forming (EMIF) method was proposed, which makes use of a small coil and small discharge energy to cause workpiece local deformation in a high speed and all local deformations accumulate into large parts.

96 citations


"An experimental study on geometric ..." refers methods in this paper

  • ...[15] used Electromagnetic incremental forming (EMIF) process to form large aluminium sheet metal parts....

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