Experimental force measurements in single point incremental sheet forming SPIF

Saidi, Badreddine; Boulila, Atef; Ayadi, Mahfoudh; Nasri, Rim

doi:10.1051/meca/2015018

Cited by 19 publications

(13 citation statements)

References 9 publications

(28 reference statements)

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“…The forming parameters, including tool radius, step size, and feed rate, were customized according to the capability of the designed CNC machine, and Table 2 outlines the control forming parameters chosen for the experiments and their design spaces with various levels. Per the central composite design (CCD) considering the face-centered option (Figure 7b), the 20 sets of the experimental runs were obtained as factorial points (1-8), star points (9)(10)(11)(12)(13)(14), and center points (15)(16)(17)(18)(19)(20), as summarized in Tables 3 and 4. Because of the 6 similar center points concerning the central composite face-centered (CCF) design, the responses were averaged from the repetition of the SPIF experiments without altering any test conditions.…”

Section: Design Of Experimentsmentioning

confidence: 99%

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Murugesan

Jung

2021

Materials

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The single-point incremental forming process (SPIF) is one of the emerging manufacturing methods because of its flexibility in producing the desired complex shapes with higher formability at low-cost compared to traditional sheet forming methods. In this research work, we experimentally investigate the forming process to determine the influence of process parameters and their contribution to enhancing the formability without causing a fracture by combining the design of experiments (DOE), grey relational analysis (GRA), and statistical analysis of variance (ANOVA). The surface morphology and the energy dispersive X-ray spectroscopy (EDS) method are used to perform elemental analysis and examine the formed parts during three forming stages. The DOE procedure, a central composite design with a face-centered option, is devised for AA3003-H18 Al alloy sheet for modeling the real-time experiments. The response surface methodology (RSM) approach is adopted to optimize the forming parameters and recognize the optimal test conditions. The statistically developed model is found to have agree with the test measurements. The prediction model’s capability in R2 is computed as 0.8931, indicating that the fitted regression model adequately aligns with the estimated grey relational grade (GRG) data. Other statistical parameters, such as root mean square error (RMSE) and average absolute relative error (AARE), are estimated as 0.0196 and 2.78%, respectively, proving the proposed regression model’s overall closeness to the measured data. In addition, the prediction error range is identified as −0.05 to 0.05, which is significantly lower and the residual data are distributed normally in the design space with variance and mean of 3.3748 and −0.1232, respectively. ANOVA is performed to understand the adequacy of the proposed model and the influence of the input factors on the response variable. The model parameters, including step size, feed rate, interaction effect of tool radius and step size, favorably influence the response variable. The model terms X2 (0.020 and 11.30), X3 (0.018 and 12.16), and X1X2 (0.026 and 9.72) are significant in terms of p-value and F-value, respectively. The microstructural inspection shows that the thinning behavior tends to be higher as forming depth advances to its maximum; the deformation is uniform and homogeneous under the predefined test conditions.

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Section: Design Of Experimentsmentioning

confidence: 99%

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Murugesan

Jung

2021

Materials

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“…A multi-component FN7325 force sensor was mounted on the work-table to measure the forming forces that occur during the process. This platform was initially developed for the incremental forming of aluminium sheets and was presented in previous paper [2]. This paper concerns the incremental forming of stainless 304L steel sheets which have a size of 200 mm x 200 mm.…”

Section: Experimental Set Upmentioning

confidence: 99%

“…But its high cost and difficult formability compared with aluminum make that the incremental forming of titanium sheet is little studied. Before the incremental forming process of stainless 304L steel sheets are used is really industrialized, studies are necessary [2][3][4][5][6]. The ISF process indeed suffers from a big slowness, geometrical inaccuracy, a not homogeneous thickness distribution which reduces its industrial suitability [1].…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet

Saidi

Giraud-Moreau

Cherouat

et al. 2017

J. Phys.: Conf. Ser.

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Abstract. AINSI 304L stainless steel sheets are commonly formed into a variety of shapes for applications in the industrial, architectural, transportation and automobile fields, it's also used for manufacturing of denture base. In the field of dentistry, there is a need for personalized devises that are custom made for the patient. The single point incremental forming process is highly promising in this area for manufacturing of denture base.The single point incremental forming process (ISF) is an emerging process based on the use of a spherical tool, which is moved along CNC controlled tool path. One of the major advantages of this process is the ability to program several punch trajectories on the same machine in order to obtain different shapes. Several applications of this process exist in the medical field for the manufacturing of personalized titanium prosthesis (cranial plate, knee prosthesis…) due to the need of product customization to each patient.The objective of this paper is to study the incremental forming of AISI 304L stainless steel sheets for future applications in the dentistry field. During the incremental forming process, considerable forces can occur. The control of the forming force is particularly important to ensure the safe use of the CNC milling machine and preserve the tooling and machinery.In this paper, the effect of four different process parameters on the maximum force is studied. The proposed approach consists in using an experimental design based on experimental results. An analysis of variance was conducted with ANOVA to find the input parameters allowing to minimize the maximum forming force. A numerical simulation of the incremental forming process is performed with the optimal input process parameters. Numerical results are compared with the experimental ones.

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“…Saidi et al studied the influence of several parameters on the evolution of the axial forming force during the incremental forming of a truncated cone. They were able to optimize the process with respect to the most influent parameters [25]. In previous studies by the authors, it was shown that predicted forces are affected by the choice of yield functions [22,23].…”

Section: Introductionmentioning

confidence: 96%

Effect of hardening law and process parameters on finite element simulation of single point incremental forming (SPIF) of 7075 aluminum alloy sheet

Esmaeilpour¹,

Kim²,

Park³

et al. 2020

Mechanics & Industry

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In the last two decades, the advances of using computers in sheet metal forming processes have introduced a novel adjustable process known as incremental sheet forming (ISF) as an optimal method for fast prototyping and low numbers of production. Formability and deformation behavior of ISF process are highly affected by the selected process parameters, such as the toolpath, step size, tool diameter, feed rate, and lubrication. The purpose of this work was to study the effect of these process parameters as well as hardening law on single point incremental forming (SPIF) process. For this work, a truncated-cone geometry was considered as a target shape with 7075-O aluminum alloy sheets. The simulations were conducted with different process parameters, i.e., toolpath type, step size, tool size, feed rate, friction coefficient, and wall angle with respect to the tool force and moment, effective plastic strain distribution and thickness of the part. In addition, three types of hardening laws i.e., isotropic extended Voce type hardening law, combined isotropic-kinematic Chaboche type hardening laws with single and double back-stress terms were applied in the finite element simulation of SPIF process. A detailed comparison of these hardening laws' predictions was made with respect to the tool force and moment, effective plastic strain distribution and thickness of the part.

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Experimental force measurements in single point incremental sheet forming SPIF

Cited by 19 publications

References 9 publications

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet

Effect of hardening law and process parameters on finite element simulation of single point incremental forming (SPIF) of 7075 aluminum alloy sheet

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