Investigation of Process Variables on Forming Forces in Incremental Sheet Forming

Abstract

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.

Forming force in incremental sheet forming: a comparative analysis of the state of the art

“…According to forming methods, ISF is categorized as single-point incremental forming (SPIF) or negative incremental forming, two-point incremental forming (TPIF) or positive incremental forming, double-sided incremental forming (DSIF) and hybrid forming [7,8]. SPIF or negative incremental forming ( Fig.…”

“…The force components F x , F y and F z along x, y and z directions, respectively, can be measured with the help of force dynamometer or load cell. In the literature, table-type force dynamometer [7,8, has mostly been used which is mounted between the machine bed and ISF fixture. The force exerted by the forming tool on the component can be simply measured by a load cell, and the measured data can be recorded with the help of data acquisition system, charge amplifier and PCbased environment (Fig.…”

“…The tool trajectory design is very important which has a direct impact on the forming force and processing time in the ISF process. Tool path determines the feasibility of safe forming of the components [7,8]. Commercial computeraided manufacturing (CAM) packages offer different types of tool paths for manufacturing applications.…”

“…Kumar et al [7] investigated the impact of sheet thickness in relation with different tool diameters on AA2024-O sheets during the SPIF process at room temperature. Results revealed that the axial peak forces increased with the increase in sheet thickness with all levels of tool diameters (7.52, 11.60, and 15.66 mm).…”

“…It was found that the predicted forces were in good agreement with the experimental results. Arfa et al [48] studied the influence of sheet thickness on AA3003-O sheets by experimental work and simulation with ABAQUS software with a set of standard Profile [2], [4][5], [30][31], [36][37][38], [56][57][58][59][60][61][62][63][64], [66][67], [69][70][71][72][73], [76][77], [81] Helical [7][8], [23], [32], [41][42][43], [68], [72], [79] Comparison of tool paths [6], [52][53][54][55] 24% (a) (b) Sudden peaks in axial forces were observed between two consecutive layers in profile tool path. In helical tool path, force variation was smooth.…”