Double-Sided Incremental Forming: A Review

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Metal matrix composites (MMCs) have a high strength-to-weight ratio, high stiffness, and good damage resistance under a wide range of operating conditions, making them a viable alternative to traditional materials in a variety of technical applications. Because of their high strength, composite materials are hard to deform to a significant depth at room temperature.As a result, additional treatments are required to enhance the composite's room ductility prior to deformation. In this investigation, as-received 6092Al/SiCp composite sheets (T6-condition) are heat treated to O-condition annealing to enhance its ductility in order to assess the influence of single point incremental forming (SPIF) parameters on the formability and fracture behavior of the Al/SiC particle composite sheets at room temperature. Then the annealed sheets are heat treated to T6-condition to enhance the strength and achieve properties equivalent to as-received sheets properties. The results demonstrate that the Al/SiC particle composite sheets with T6 treatment could not be deformed to the specified depth at room temperature due to low room ductility and that further treatment, such as Ocondition annealing, is required to enhance the room ductility. When annealed Al/SiCp composite sheets are heat treated to T6, the sheets exhibit properties comparable to the asreceived sheets. Al/SiC particle composite sheets with low SPIF parameters may have greater formability and fracture depth with low strain hardening curve.

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigation of formability in incremental sheet forming of particle-reinforced metal matrix composite sheets

Gatea

Tawfiq

2022

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“…Ai and Long [16] summarised the material fracture mechanism and behaviour in ISF. Taleb-Araghi et al [17], Liu et al [18] and Peng et al [19] reviewed the development of variants of ISF including hybrid ISF, heat-assisted ISF and DSIF.…”

Section: Introductionmentioning

confidence: 99%

Incremental sheet forming of thermoplastics: a review

Zhu

Popov

2020

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Incremental sheet forming (ISF) is a promising flexible manufacturing process, which has been tested in sheet forming of various metallic materials. Although ISF-based forming of thermoplastics is relatively new, it has drawn considerable interests and significant progress has been made in recent years. This paper presents a review of concurrent research on the emerging trend of thermoplastic-focused ISF processes. Attention is given to the processing conditions including process setup, process parameters and forming forces. The deformation mechanism and failure behaviour during ISF of thermoplastics are evaluated, which leads to detailed discussions on the formability, effect of different process parameters and the forming quality such as geometric accuracy, surface finish and other consideration factors in ISF of thermoplastics. A comparison of important similarities and differences between ISF of thermoplastic and metallic materials is made. Finally, a brief discussion is provided on the technical challenges and research directions for ISF of thermoplastic materials in the future.

“…In this process, a sheet metal is clamped along its periphery and simple tool(s) moving in a predefined path progressively deforms the sheet to required geometry. Advantages of ISF process include higher formability, less lead time and suitability for low volume production [1][2][3][4][5]. The simple variant of ISF, Single Point Incremental Forming (SPIF), uses single tool to form the geometry from one side of sheet without any support from other side as shown in Fig.…”

Section: Introductionmentioning

confidence: 99%

Enhancement of accuracy in double sided incremental forming by compensating tool path for machine tool errors

Konka

Lingam

Singh

et al. 2020

Incremental Sheet Forming (ISF) is a dieless forming process and has capability to form complex 3D geometries. Double Sided Incremental Forming (DSIF) is the most flexible variant of ISF as it uses two tools, one on either side of the sheet (one tool forms the sheet and other acts as support). However, forming the components with acceptable accuracy is one of the challenges as it depends on many factors such as sheet and tool(s) deflections as well as machine tool errors. If these deflections/deviations are not compensated in tool path, accuracy of the component gets affected and support tool may lose contact or squeeze the sheet while forming components. In the present work, grid-based method is used to measure the machine tool error at discrete points of the work envelope. To enhance the accuracy and support tool contact condition, machine tool errors are compensated in tool path along with tool and sheet deflection compensations developed earlier. To demonstrate the effectiveness of developed methodology on the accuracy, components having different geometric characteristics as well as opening sizes are formed with and without compensating for machine tool errors in tool path. Results indicate that deviation in symmetry within the same contour reduced from 850 μm to less than 40 μm. In addition, support tool has maintained contact throughout support surface with maximum force of 50 N when machine tool errors are compensated.