Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments

Mulay, Amrut; Ben, B. Satish; Ismail, Syed; Kocańda, A.

doi:10.1007/s40430-016-0703-7

Cited by 45 publications

(13 citation statements)

References 29 publications

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“…This process in comparison with the conventional forming processes carries significant improvements in terms of process flexibility, customization and complexity of products produced at low industrial costs. However, it has some serious limitations which constraints its implementation on shop floor and hinders it in reaching the mainstream [1]. The process suffers from high forming time.…”

Section: Introductionmentioning

confidence: 99%

Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation

Shrivastava

Kumar

Tandon

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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The work involves finite element analysis (FEA) and experimental investigation of formability and geometrical accuracy prevailing in single point incremental forming (SPIF) process. Preheating at different temperatures was performed in order to reform microstructures (grain size) and texture (spatial grain orientation distribution) of AA1050 sheet. Preheating led to removal and rearrangements of defects in the crystal structure in comparison with the distorted structures present in coldworked commercial aluminum sheets. Preheating at higher temperatures resulted in coarser grains with preferential texture and increased area fraction of homogenously oriented grains. Numerical simulation of SPIF process has been done to predict the effect of preheating on von Mises stresses, forming load, wall thickness distribution and geometrical accuracy of formed parts. For the purpose, Johnson-Cook models' parameters were evaluated by mechanical characterization of the samples with varying microstructural and texture arrangements resulted due to variations in preheating temperatures. FEA of the process revealed that preheating of the sheets resulted in reduced forming load, uniform wall thickness distribution and improved geometrical accuracy. The results were further validated by experiments and compared to the original samples with fine and randomly orientated grains.

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Section: Introductionmentioning

confidence: 99%

Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation

Shrivastava

Kumar

Tandon

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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show abstract

“…The larger the forming limit angle, the greater the amount of deformation that the sheet can produce, and the higher the forming performance. In the experiment, the forming limit angle was used as the standard for the forming performance of the material [25][26][27].…”

Section: Forming Limit Analysismentioning

confidence: 99%

Analysis of Deformation Characteristics of AZ31B Friction Heating Incremental Forming

Wang¹,

Zhou²,

2020

Preprint

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A friction heating incremental forming (FHIF) is proposed, which does not require external heating. By means of orthogonal experimental, finite element analysis and CATIA reverse engineering methods, the forming characteristics of magnesium alloy AZ31B FHIF are studied, such as forming limit angle, dimensional accuracy, thickness distribution, equivalent stress and equivalent strain at different forming stages. The results show that: For the FHIF, the forming limit angle can be up to 76°, and the most obvious way to increase the forming limit angle is to increase the spindle speed. In the FHIF, due to the limitations of the experimental conditions, it will be different from the ideal model. The bending phenomenon first occurs in the early stage of forming, which makes the upper corner part the worst accuracy, and the lower corner part obvious defects. Compared with the theoretically stable thickness, the actual part sidewall is thinned by 11%. The simulation successfully predicts and observes the thickness change and stress-strain change trend of the entire FHIF.

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“…1. ISF working principle [2], adapted from [3] continuous development, and for its improvement, in addition to experimental research, more modern techniques for the design of experiments (DOE) or finite element methods (FEM) are used [1] and [4].…”

Section: Integrating a New Software Tool Used For Tool Path Generatiomentioning

confidence: 99%

“…In recent years, flexible manufacturing processes have gained increased attention from researchers and producers. Incremental sheet forming (ISF) is a "dieless" and flexible manufacturing process from the cold-pressing industry, used for customized products, rapid prototyping, and small batch production series of sheet metal parts [1] and [2].…”

Section: Introductionmentioning

confidence: 99%

Integrating a New Software Tool Used for Tool Path Generation in the Numerical Simulation of Incremental Forming Processes

Nasulea¹,

Oancea²

2018

SV-JME

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In the incremental sheet forming simulation, finite element modelling typically was used to anticipate material behaviour, predict deformation forces, thickness reduction or to identify other information. Because the forming tool motions are difficult to be implemented in finite element method (FEM) software systems, and because of the large number of points that describe the tool path, in order to reduce data preparation time, this paper presents the implementation of a new software tool conceived by the authors in the process of the numerical simulation of incremental sheet forming. The software tool uses a CNC file in G-code format to reveal the interpolation point coordinates of the tool motions and the positioning time in a specific ANSYS format. Usually, a tool path for an incremental sheet forming process consists of thousands of interpolation points and is very difficult and time-consuming to implement manually into a FEM software system. The new software tool solves this issue, at least for ANSYS software, being swift and easy to use. The paper also presents how the software tool is integrated and validated in a case study of an incremental sheet forming process simulation concerning different part configurations.

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Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments

Cited by 45 publications

References 29 publications

Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation

Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation

Analysis of Deformation Characteristics of AZ31B Friction Heating Incremental Forming

Integrating a New Software Tool Used for Tool Path Generation in the Numerical Simulation of Incremental Forming Processes

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