Experimental Investigation on Geometric Error in Single-Point Incremental Forming with Dummy Sheet
01 Jan 2021-pp 81-92
TL;DR: In this paper, the 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.
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.
References
More filters
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
TL;DR: In this article, the possibility of employing the single point incremental forming technology currently being developed for flexible sheet metal forming applications, for producing low cost, small-batch, high-quality polymeric sheet components is discussed.
137 citations
TL;DR: The investigation of the influence of the process parameters on accuracy through a reliable statistical analysis is focused on and some effective actions are implemented to improve the accuracy taking into account a simple case study.
114 citations
01 Feb 2005
TL;DR: In this article, a methodology for identifying applications of a new production technology is proposed and tested, applied to the incremental sheet-forming process, showing a preference for low-volume high-value applications and identifying the importance of improving process accuracy.
Abstract: A methodology for identifying applications of a new production technology is proposed and tested. It is applied to the incremental sheet-forming process, showing a preference for low-volume high-value applications and identifying the importance of improving process accuracy. The methodology could in future help to identify novel applications.
112 citations
TL;DR: A new approach to generate and control Intelligent CAM programmed tool paths is proposed to use process constraints for programming and controlling the tool path, which are adapted during the running of the CNC program according to real-time process data evaluation.
Abstract: Incremental sheet forming is an emerging process to manufacture sheet metal parts that is well adapted for small batch production or prototypes. The adjustment time is short, as it is sufficient to modify the tool motions to optimize the manufacturing process. Tool path generation therefore becomes a key topic linked to incremental sheet forming, and process characteristics ask for dedicated tool paths. Hence, this paper first discusses the impact of tool path types and other programming parameters on process implementation through an experimental campaign performed on a parallel kinematics machine tool. Then, a new approach to generate and control Intelligent CAM programmed tool paths is proposed. The major purpose of this innovative concept is to use process constraints for programming and controlling the tool path, which are adapted during the running of the CNC program according to real-time process data evaluation. Validation studies and an industrial implementation are finally presented to assess the efficiency of the proposed approach.
106 citations