Integration of design rules and process modelling within SPIF technology-a review on the industrial dissemination of single point incremental forming

Afonso, Daniel; Sousa, Ricardo J. Alves de; Torcato, Ricardo

doi:10.1007/s00170-017-1130-3

Cited by 30 publications

(13 citation statements)

References 32 publications

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“…In conclusion, the feature-based strategy is a useful method to optimize the toolpath with different geometrical features. The feature-based strategy can be generalized in the form of detailed guidelines of toolpath design in the DSIF process, similar to the study presented in SPIF [15]. Two essential issues to be addressed are the separation of the contour model and the implementation of compensation.…”

Section: Feature-based Toolpath Strategymentioning

confidence: 99%

“…However, the SPIF process is also limited by the slow-forming speed, insufficient accuracy, rough surface finishing, and small achievable wall angle [9]. A number of reviews focus on specific aspects of ISF processes such as the effects of the process parameters [12], hardware [13], asymmetric incremental sheet forming [14], toolpath strategies [15], and FEA research [11]. Future prospects were also suggested in terms of the mechanism studies, prediction by FE simulations, and the extension of small-scale production and industrial applications [11].…”

Section: Introductionmentioning

confidence: 99%

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Double-Sided Incremental Forming: A Review

Peng

Becker

2019

Journal of Manufacturing Science and Engineering

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Incremental sheet-forming (ISF) processes have been developed rapidly in the past two decades. Its high flexibility and easy operability have a significant appeal for industrial applications, and substantial progress has been made in fundamental understanding and demonstration of practical implementation. However, there are a number of obstacles including achievable accuracy and instability in material deformation, which are considered as a main contributing factor for preventing the ISF process to be widely used in industry. As a variant of the general ISF process, double-sided incremental forming (DSIF) uses an additional supporting tool in the opposite side of the workpiece, maintains the flexibility, and at the same time improves the material deformation stability and reduces material thinning. In recent years, there has been increased research interest in looking into DSIF-specific material deformation mechanisms and investigation. This paper aims to provide a technical review of the DSIF process as benchmarked with single-point incremental forming (SPIF). It starts with a brief overview of the current state of the art of both SPIF and DSIF. This is followed by a comparative study between SPIF and DSIF with the key research challenges identified. This leads to a recommendation of future directions for DSIF focused research.

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Section: Feature-based Toolpath Strategymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Double-Sided Incremental Forming: A Review

Peng

Becker

2019

Journal of Manufacturing Science and Engineering

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“…Ambrogio et al [ 3 ] report this in cases from medicine and Milutinović et al [ 4 ] in case studies from dentistry. Since the process is rather distinct in comparison to other processes of sheet metal forming, special design rules were presented by Afonso et al [ 5 ]. The process was first used solely for the production of metal parts [ 6 , 7 , 8 ], but in recent years, various polymer materials have also been successfully processed by IF technologies [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

et al. 2022

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Single point incremental forming (SPIF) is one of the most promising technologies for the manufacturing of sheet metal prototypes and parts in small quantities. Similar to other forming processes, the design of the SPIF process is a demanding task. Nowadays, the design process is usually performed using numerical simulations and virtual models. The modelling of the SPIF process faces several challenges, including extremely long computational times caused by long tool paths and the complexity of the problem. Path determination is also a demanding task. This paper presents a finite element (FE) analysis of an incrementally formed truncated pyramid compared to experimental validation. Focus was placed on a possible simplification of the FE process modelling and its impact on the reliability of the results obtained, especially on the geometric accuracy of the part and bottom pillowing effect. The FE modelling of SPIF process was performed with the software ABAQUS, while the experiment was performed on a conventional milling machine. Low-carbon steel DC04 was used. The results confirm that by implementing mass scaling and/or time scaling, the required calculation time can be significantly reduced without substantially affecting the pillowing accuracy. An innovative artificial neural network (ANN) approach was selected to find the optimal values of mesh size and mass scaling in term of minimal bottom pillowing error. However, care should be taken when increasing the element size, as it has a significant impact on the pillow effect at the bottom of the formed part. In the range of selected mass scaling and element size, the smallest geometrical error regarding the experimental part was obtained by mass scaling of 19.01 and tool velocity of 16.49 m/s at the mesh size of 1 × 1 mm. The obtained results enable significant reduction of the computational time and can be applied in the future for other incrementally formed shapes as well.

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“…It has also been proved that SPIF can be applicable for wide range of materials in industry such as steel, titanium, brass, and aluminium alloys [8] . SPIF also has contributions in various fields of industry such as aerospace, automotive, and even biomedical.…”

Section: Introductionmentioning

confidence: 99%

Integrating CAM and numerical simulation to investigate single point incremental forming of Al6061

Shaaban

Elakkad

2020

Eng. Sci. and Milit. Techno.

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Single point incremental forming, SPIF, is a forming process that has a great potential application in sheet metal industries. SPIF is capable of producing medium size batches of complex shapes with low cost as it requires no die. This study explores the potentials of integrating computer aided manufacturing, CAM, and finite element analysis, FEA, to obtain a virtual model that realistically simulates the SPIF process. The simulation of SPIF process has been carried out using LS-Dyna4.3 © software while producing a circular and rectangular taper pockets on a blank made of AL6061. The tool path has been generated using a CAM software and imported to a CNC machine to execute the SPIF process, taking into consideration the main forming parameters: the feed rate and the incremental step size. The results of both simulation and experiment are presented against each other in terms of thickness reduction, springback, and cross-sectional profile, and they are proved to be close within an accepted range. The virtual model obtained in this study is believed to be useful for performing an optimization analysis to decide the optimum forming parameters that are thought to affect the SPIF process.

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Integration of design rules and process modelling within SPIF technology-a review on the industrial dissemination of single point incremental forming

Cited by 30 publications

References 32 publications

Double-Sided Incremental Forming: A Review

Double-Sided Incremental Forming: A Review

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

Integrating CAM and numerical simulation to investigate single point incremental forming of Al6061

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