Deformation mechanics and efficient force prediction in single point incremental forming

Li, Yanle; Daniel, William J.T.; Liu, Zhaobing; Lu, Haibo; Meehan, Paul A.

doi:10.1016/j.jmatprotec.2015.02.009

Cited by 68 publications

(38 citation statements)

References 24 publications

(34 reference statements)

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“…Despite that shear deformation was assumed as the main deformation mechanism, this approach was shown to be effective for predicting the tangential forming force. Based on Mirnia's work, Li et al [13,14] further developed the model to take into account bending and stretching deformation modes and verified the model with experimental tests. However, the contribution between each deformation modes needs to be further investigated and quantified.…”

Section: Introductionmentioning

confidence: 99%

Deformation analysis in single-point incremental forming through finite element simulation

Daniel

Meehan

2016

Int J Adv Manuf Technol

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Incremental sheet forming (ISF) is a promising manufacturing technology in which complex 3D shapes can be formed with one simple tool. Compared to conventional forming processes, for complex shapes, it is more flexible and economical with higher formability and shorter lead time. Therefore, ISF is ideally suitable to rapid prototype and small-batch production, especially in the aerospace and biomedical sectors. Over the last decade, although the process has been experimentally studied extensively, the associated deformation mechanics is still unclear and intensive investigation is needed. The purpose of this study is to provide further knowledge of the deformation mechanics of the sheet and clarify the deformation mechanism in a typical cone-forming process through finite element (FE) simulation approach. In particular, comprehensive FE models with fine solid elements are utilised, which allow the investigation of deformation modes including stretching, bending and shearing. The FE model is firstly validated with experimental results in terms of forming forces, and then, the evolution history of all the strain components along with the effective strain is presented. The contribution of each strain component to the effective plastic strain during the cone-forming process is discussed. Moreover, the characteristic of each strain component is investigated in detail. It is confirmed from the FE simulation that the deformation modes in the ISF process are a combination of shearing, bending and stretching, although the quantitative contributions in each direction are varied. The effect of step-down size on material plastic deformation as well as formability is also investigated.

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Section: Introductionmentioning

confidence: 99%

Deformation analysis in single-point incremental forming through finite element simulation

Daniel

Meehan

2016

Int J Adv Manuf Technol

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“…Aerens et al [8] studied effects of tool diameters on AA3003 sheets and showed that tangential force (F t ) is small and remains nearly constant but force in z-direction increase with tool diameter. Al-Obaidi et al [9] studied influences of feed rate with induction heating on forming force on DC04 sheets and showed that at 35 kW power and a feed rate of 2500 mm/min, force values was higher (approx. 1450 N) than force value (approx.…”

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confidence: 99%

Investigation of Process Variables on Forming Forces in Incremental Sheet Forming

Kumar¹,

Gulati²,

Kumar³

2018

IJET

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Abstract-Manufacturing of small batch size products and prototypes are not economical using conventional forming processes as these processes require dedicated and highly specialized equipments such as forming presses, dies, and punches. Incremental Sheet Forming (ISF) process has been confirmed as quiet economical process for rapid prototyping and batch type production. In this work, process variables are investigated on axial peak forces on AA2024-O sheets. A strain gauge based dynamometer has been used to record axial peak forces during incremental process. Combination of higher wall angle and higher tool diameter leads to larger axial forces which can be limitation of the capacity of the machine tool and forming tools used in the process. Higher sheet thickness not only requires larger forming forces to form the components but also increases formability of the material.

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“…This was confirmed by both experimental measurements and theoretical analysis. Previous experimental results [26] showed that the tangential forming force is linearly proportional to the sheet thickness in the forming of the truncated cone. Moreover, according to the calculation of plastic deformation power in [27], the power has a linear relation with the sheet thickness under both shear and stretching deformation modes.…”

Section: Deformation Energymentioning

confidence: 90%

Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

Daniel

et al. 2015

Int J Adv Manuf Technol

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Incremental sheet forming (ISF) is a promising manufacturing process that features benefits of reduced forming forces, enhanced formability and greater process flexibility. It also has a great potential to achieve economic payoff for rapid prototyping applications and for small quantity production in various applications. However, limited research has been conducted from the sustainability point of view, particularly for energy consumption. More consumed energy will generate more heat and affect tool and product wear. Also, geometric accuracy is still one of the dominant limits for the further development and commercialization of the ISF technology. Therefore, the aim of this study is to investigate how different process parameters affect the consumed energy during the forming process and also find the optimal working condition for lower deformation energy with higher geometric accuracy. A Box-Behnken design of 27 tests for pyramidforming processes have been performed for a multi-objective optimisation that considers four factors: step down, sheet thickness, tool diameter and wall angle at three levels. The deformation energy during the forming process was calculated based on the measured forming forces. It was found that the deformation energy heavily depends on the sheet thickness because of higher plastic energy required to deform the material. Increasing step-down size within a limited range or decreasing the wall angle is also an effective approach to reduce the deformation energy. Moreover, the effects of various process parameters on the global geometric accuracy have also been investigated. The geometric error has been empirically predicted by quadratic equations giving the influence of the most influential forming parameters. It was concluded that the geometric quality is largely determined by the quadratic effect of wall angle, the linear effect of sheet thickness and the interaction effect of thickness and step down. Finally, the optimal working conditions for both independent and simultaneous minimisation of deformation energy and geometric error during the pyramid-forming process are provided.

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Deformation mechanics and efficient force prediction in single point incremental forming

Cited by 68 publications

References 24 publications

Deformation analysis in single-point incremental forming through finite element simulation

Deformation analysis in single-point incremental forming through finite element simulation

Investigation of Process Variables on Forming Forces in Incremental Sheet Forming

Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

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