Analysis of geometric accuracy and thickness reduction in multistage incremental sheet forming using digital image correlation

Gonzalez, Mercedes M.; Lutes, Nathan; Fischer, Joseph D.; Woodside, Mitchell R.; Bristow, Douglas A.; Landers, Robert G.

doi:10.1016/j.promfg.2019.06.105

Cited by 19 publications

(11 citation statements)

References 13 publications

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“…Thickness distribution/uniformity/homogeneity in ISF has become a critical issue, and several studies have been conducted in this area. It is worth mentioning that to overcome sheet thinning and improve thickness distribution, multistage forming strategies have been the approach typically used in ISF [61,151,154,172,173]. Nevertheless, it is still questionable which method can reduce thin- Micari et al [164] hinted that the reduced component accuracy of articles formed by ISF results from the following two typologies of error: springback in the wall and the pillow effect on the minor undeformed base.…”

Section: Thickness Distributionmentioning

confidence: 99%

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Trzepieciński

Najm

Oleksik

et al. 2022

Metals

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Due to a favourable strength-to-density ratio, aluminium and its alloys are increasingly used in the automotive, aviation and space industries for the fabrication of skins and other structural elements. This article explores the opportunities for and limitations of using Single- and Two Point Incremental Sheet Forming techniques to form sheets from aluminium and its alloys. Incremental Sheet Forming (ISF) methods are designed to increase the efficiency of processing in low- and medium-batch production because (i) it does not require the production of a matrix and (ii) the forming time is much higher than in conventional methods of sheet metal forming. The tool in the form of a rotating mandrel gradually sinks into the sheet, thus leading to an increase in the degree of deformation of the material. This article provides an overview of the published results of research on the influence of the parameters of the ISF process (feed rate, tool rotational speed, step size), tool path strategy, friction conditions and process temperature on the formability and surface quality of the workpieces. This study summarises the latest development trends in experimental research on, and computer simulation using, the finite element method of ISF processes conducted in cold forming conditions and at elevated temperature. Possible directions for further research are also identified.

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Section: Thickness Distributionmentioning

confidence: 99%

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Trzepieciński

Najm

Oleksik

et al. 2022

Metals

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“…Besides, Mecedes et al examined the geometric accuracy and thickness distributions using the DIC technique for studying the performance of multistage incremental sheet forming in formability, accuracy and uniform level of sheet thickness. The experimental setup, the image of the form and the corresponding 3D thickness model based on DIC data are shown in Figure 8(a-c), respectively (Mercedes et al, 2019). Wang et al compared several different DIC procedures to establish an FLD and proposed a DIC-based time-dependent measurement method for the forming limit strains.…”

Section: Errors Affecting Dic Measurementsmentioning

confidence: 99%

Digital image correlation for sensing kinematic fields in manufacturing processes: a review

Zhu

Zhang

Zou

2021

JIMSE

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PurposeThe purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the area of manufacturing.Design/methodology/approachNo methodology was used because the paper is a review article.Findingsno fundings.Originality/valueHerein, the historical development, main strengths and measurement setup of DIC are introduced. Subsequently, the basic principles of the DIC technique are outlined in detail. The analysis of measurement accuracy associated with experimental factors and correlation algorithms is discussed and some useful recommendations for reducing measurement errors are also offered. Then, the utilization of DIC in different manufacturing fields (e.g. cutting, welding, forming and additive manufacturing) is summarized. Finally, the current challenges and prospects of DIC in intelligent manufacturing are discussed.

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“…So, thickness distribution is a critical factor for designing and controlling the incremental forming operations [ 5 , 6 ]. It is known that the sine law, verified on truncated cones, truncated pyramids and other simple formed parts is a concise model for prediction of thickness in the IF process [ 7 , 8 , 9 , 10 , 11 , 12 ]. Bambach presented a variant of the sine law by assuming that the sheet deforms along the normal direction of the smooth transient surface [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

A Novel Algorithm for Thickness Prediction in Incremental Sheet Metal Forming

Wang

Zhang

et al. 2022

Materials

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Incremental sheet metal forming characterized as increased flexibility and local plastic deformation is well suitable for low-production-run manufacturing and a new sample trial production of complex shapes. Thickness thinning is still an obstacle to the application of incremental forming. In this study, a novel mathematical algorithm based on a non-uniform rational B-spline (NURBS) surface was proposed and implemented which focuses on predicting and calculating the final thickness for arbitrary parts in incremental forming. In order to evaluate the validity of the proposed model, the finite element simulation and forming experiments of three kinds of parts, such as truncated cones, truncated pyramids and ellipsoid parts, were conducted. The thickness of theoretical prediction was compared with that of finite element simulation and experiment, and good agreements were obtained. The results show that the proposed model and the method are effective and robust for predicting the thickness of the formed parts in incremental sheet metal forming.

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Analysis of geometric accuracy and thickness reduction in multistage incremental sheet forming using digital image correlation

Cited by 19 publications

References 13 publications

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

Digital image correlation for sensing kinematic fields in manufacturing processes: a review

A Novel Algorithm for Thickness Prediction in Incremental Sheet Metal Forming

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