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Book ChapterDOI

Hybrid Incremental Forming: Investigation on Localized Thinning and Thickness Distribution in Formed Parts

TL;DR: In this article, a hybrid incremental sheet forming (HISF) process comprising stretch forming followed by single point incremental sheet formation (SPIF) is developed for forming conical frustum.
Abstract: In the present experimental work, hybrid incremental sheet forming (HISF) process comprising stretch forming followed by single point incremental sheet forming (SPIF) is developed for forming conical frustum. Experimental investigation is done to find the influence of process parameters on thickness distribution and localized thinning in the formed parts. Experimental result reveals that stretching has a substantial effect on localized thinning in formed parts. Small improvement in the thickness distribution and localized thinning is found in formed parts. Experimental investigation on the influence of preform tool shape is also done to further improve thickness distribution. It is observed that the geometry of preform tool and amount of stretching has a great influence on thinning and thickness distribution. It is found that intermediate preform tool size and small amount of preforming results in forming conical frustum having uniform thickness distribution. Also, a considerable reduction in forming time using developed HISF process is observed as compared to SPIF process alone.
Citations
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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

References
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Journal ArticleDOI
TL;DR: Asymmetric Incremental Sheet Forming has the potential to revolutionize sheet metal forming, making it accessible to all levels of manufacturing as discussed by the authors, and has been shown to be a state-of-the-art in sheet metal manufacturing.

973 citations

Journal ArticleDOI
TL;DR: In this article, a new method is proposed for hot incremental forming, which makes use of electric current for heating hard-to-form sheet metals at the tool-sheet interface in order to fully utilize the formability of these materials.
Abstract: In the current work, a new method is proposed for hot incremental forming. The method is based on simple tooling and is easy to employ. It makes use of electric current for heating hard-to-form sheet metals at the tool–sheet interface in order to fully utilize the formability of these materials. The potential effect of processing parameters, namely current, tool size, feed rate and step size, on the formability are investigated using AZ31 magnesium. In addition to this, the shape distortion of TiAl2Mn1.5 titanium workpiece after hot forming has also been addressed herein. Experimental results demonstrate that this technique is feasible and easy to control.

179 citations

Journal ArticleDOI
TL;DR: In this paper, a new hybrid process, the combination of AISF and stretch forming, is presented that shows the positive impact of this hybrid process on the process limits, including material thinning, geometric accuracy and the process duration.

149 citations

Journal ArticleDOI
01 Nov 2004
TL;DR: In this article, a double-pass incremental forming method was proposed as a way to modify the final thickness profile of steep geometry, allowing the production of parts that thin to failure with single-pass techniques.
Abstract: Single-point incremental forming is an innovative sheet metal forming method employing a standard computer numerical controlled (CNC) vertical milling machine and basic tooling. Traditionally the part is formed with a single-pass tool-path technique. A double-pass technique has been proposed as a way to modify the final thickness profile of steep geometry. Wall thickness profiles of a series of test cones have been measured and have shown that the formation of the characteristic thinning band present in single-pass forming can be delayed. Double-pass forming can allow the production of parts that thin to failure with single-pass techniques.

144 citations

Journal ArticleDOI
TL;DR: Incremental sheet forming (ISF) is an emerging metal-forming technology in which the tool motion is controlled numerically as discussed by the authors, and it is economical to form complex parts in small to medium batches and provides a short and inexpensive way of forming products having a relatively simple but interesting shape.
Abstract: Incremental sheet forming (ISF) is an emerging metal-forming technology in which the tool motion is controlled numerically. The process is economical to form complex parts in small to medium batches and provides a short and inexpensive way of forming products having a relatively simple but interesting shape. In this article, a review of the present state-of-the-art technologies and the potential applications of incremental sheet metal forming are presented in brief. This article seeks to address the approaches and methods that are prevalently applied. Furthermore, the article also seeks to guide researchers for future work, by identifying inadequacies of the current approaches and potential for valuable contributions in the field of incremental forming.

140 citations