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Book ChapterDOI

Experimental Investigation on Geometric Error in Single-Point Incremental Forming with Dummy Sheet

01 Jan 2021-pp 81-92
Abstract: Single-point incremental forming (SPIF) process is an emerging sheet metal forming process in which constraint of using dedicated press tools is eliminated. Some process limitations like poor surface finish, longer forming time, higher geometrical error, and uneven wall thickness distribution restrict its applicability in sheet metal industry. But SPIF process with dummy sheet has the capability to overcome some of the prevailing limitations of SPIF process. In the present paper, influence of dummy sheet thickness, step size, wall angle, and feed rate on geometrical error in terms of root-mean-squared error (RMSE) of formed part is investigated. Box Behnken design is used to design the experiments. From the analysis of experimental result, it is found that dummy sheet thickness, step size, and wall angle are significant process parameters influencing RMSE. No significant influence of feed rate on RMSE is observed. RMSE increases with increase in dummy sheet thickness and wall angle, while it decreases with increases in step size. As feed rate increases, there is nominal decrease in RMSE which is desirable. So higher feed rate is recommended to reduce forming time. Further, empirical model is developed to predict RMSE. Also, optimization of process parameters is performed to minimize RMSE. Confirmation experiments were performed in order to check the accuracy of developed predictive model and it is found that predicted results are in good agreement with experimental results.

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Topics: Sheet metal (51%)
References
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Journal ArticleDOI
01 Jan 2004-CIRP Annals
Abstract: Incremental Sheet Forming (ISF) is a process capable of producing complex sheet components by the CNC movement of a simple tool in combination with simplified dies. Earlier work revealed two major process limits, namely the limitation on the maximum achievable wall angle, and the occurrence of geometric deviations. The work detailed in this paper focuses on forming strategies to overcome these process limits, including the processing of tailor rolled blanks. Additionally, finite element modelling of the process is presented and discussed with respect to the prediction of the forming limits of ISF.

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206 citations


Journal ArticleDOI
01 Jan 2008-CIRP Annals
Abstract: This paper presents a closed-form theoretical analysis modelling the fundamentals of single point incremental forming and explaining the experimental and numerical results available in the literature for the past couple of years. The model is based on membrane analysis with bi-directional in-plane contact friction and is focused on the extreme modes of deformation that are likely to be found in single point incremental forming processes. The overall investigation is supported by experimental work performed by the authors and data retrieved from the literature.

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200 citations


Journal ArticleDOI
Abstract: The paper is aimed to discuss some relevant issues concerning an innovative sheet metal forming technology, namely Single Point Incremental Forming. The advantages of this technology are addressed, including its capability to provide effective answers to some impellent industrial requirements: process flexibility, strong customer orientation, production of highly differentiated goods at low industrial costs. As well some relevant drawbacks are highlighted, mainly as concerns the level of accuracy permitted by the process. 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. Finally, some strategies for error minimisation are presented and discussed.

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197 citations


Journal ArticleDOI
Giuseppina Ambrogio1, I. Costantino2, L. De Napoli1, Luigino Filice1  +2 moreInstitutions (2)
Abstract: As known, incremental forming is a flexible and innovative sheet metal forming process which allows complex shape shells forming without the need for any die. For these reasons, incremental forming is nowadays suggested for rapid prototyping and customised products. The present paper is focused on material formability in incremental forming and, in particular, on the evaluation and compensation of elastic springback. The latter significantly modifies the imposed shape. For this purpose, a deeper assessment of the process was developed following three different approaches. First of all, a wide experimental investigation on the influence of some relevant process parameters was developed. At the same time, an explicit FEM analysis of incremental forming process was carried out in order to verify its effectiveness and, as a consequence, its ability to be used as a design tool. Furthermore, the obtained parts were analysed by a reverse engineering technique and the measured geometry was numerically compared with the desired one, with the aim to quantify the geometrical discrepancies. In this way, an integrated numerical/experimental procedure is proposed in order to limit the shape defects between the obtained geometry and the desired one.

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158 citations


Journal ArticleDOI
Abstract: Asymmetric sheet incremental forming is a relatively recent sheet metal forming process introduced to reduce the costs of sheet metal forming when low volume batches, customized parts or prototypes have to be manufactured. In recent years, this forming process saw a very fast development, thanks to the researches conducted by many international research centres considering different process configurations and part geometries. The present work deals with the optimization of the tool path in two point sheet incremental forming with full die, in a particular asymmetric sheet incremental forming configuration. The aim of the study is the experimental evaluation and optimization of the tool path, in order to reproduce an automotive component with the best dimensional accuracy, the best surface quality and the lowest sheet thinning.

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144 citations