Investigation of Surface Roughness in Incremental Sheet Forming

Gulati

J Braz. Soc. Mech. Sci. Eng.

et al. 2019

Self Cite

Incremental sheet forming (ISF) significantly exempts use of expensive dies and reduces tooling cost for manufacturing complex parts in the field of sheet metal forming which makes it suitable for manufacturing prototypes and low volume production as compared to other traditional sheet metal forming processes. ISF also finds suitability for producing components of old machinery, which are otherwise very difficult to form due to the unavailability of forming dies. Moreover, the incremental nature of the process and local deformation of the sheet ensures higher formability and lower required forming force. To take advantages of lower required forming force, it is important to minimize and estimate forming force through the manipulation of the parameters for the safe utilization of hardware. In this review article, a literature survey was carried out quantitatively to study different aspects of ISF, especially to show different process parameters and techniques that affect the forming forces significantly. The current state of the art of the ISF process has been discussed with detailed analysis of process capabilities and limitations in terms of forming forces. Influences of different process parameters and forming techniques have also been studied on forming forces. Some parameters have shown their significance to control the forming force in order to preserve forming machinery. A lack of focus was found on effects of some important forming process parameters and methods, which could have been crucial for safe utilization of forming hardware. A number of guidelines have been recommended for future research work. Appropriate guidelines have also been suggested regarding the relationship between process parameters and forming forces developed during the process in order to ensure the applicability of the ISF process on the industrial scale.

Section: Influence Of Lubricationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

Gulati

J Braz. Soc. Mech. Sci. Eng.

et al. 2019

Self Cite

“…In other words, surface quality increases as the forming tool diameter increases. Kumar and Gulati, [ 25 ] in their study, stated that the reduction of tool diameter increased surface roughness.…”

Section: Resultsmentioning

confidence: 99%

Optimization of Incremental Forming of Low‐Alloy High‐Yield‐Strength HC300LA Sheet Using a Rolling Blank Holder Method

Taşdemir

2020

steel research int.

Incremental sheet metal forming is a method that enables the fast and flexible production of complex geometric parts using a very simple set of forms. However, this method presents some problems including wall thickness and spring‐back. Different methods are developed to solve these problems. One of these, the rolling blank holder method, is applied in this study using a 1 mm‐thick HC300LA sheet. The effects of holding pressure, increment size, forming tool diameter, and feed rate parameters on spring‐back, wall thickness, surface roughness, and forming force are investigated in the experiments conducted using the two‐point incremental forming‐rolling blank holder (TPIF‐RL) sheet‐forming method. The effects of the selected parameters are optimized using response surface methodology. As a result of the study, it is determined that the most important parameter for surface quality and wall thickness is the forming tool diameter, the most effective parameters for forming force are the forming tool diameter and increment size, and for spring‐back the dominant parameters are forming tool diameter, holding pressure, and increment size. The spring‐back angle increases with increasing forming tool diameter, holding pressure, and feed rate. In addition, both spring‐forward and spring‐back are observed in the formed parts.

Advances in Materials Science

“…The main advantages of single point incremental forming (SPIF), which is a very flexible sheet forming process, are [1,2]: no need to manufacture the dies, the ability to shape elements on a conventional numerically-controlled milling machine, a much lower forming force compared to conventional deep drawing, flexibility of production, a higher value of sheet deformation in relation to die forming, and that constructional changes in the formed elements can be quickly and easily taken into consideration [3][4][5]. Incremental forming technology is characterised by a few limitations compared to the conventional sheet forming methods, like a low geometric accuracy of elements, significant springback of the drawpieces, longer duration of forming times and the economic justification for it when using it in smalllot production [6].…”

Section: Introductionmentioning

confidence: 99%

Experimental Analysis of Single Point Incremental Forming of Truncated Cones in DC04 Steel Sheet

Krasowski

Kubit

Trzepieciński

et al. 2020

Experimental tests to form truncated cones were carried out on a 3-axis milling machine. 0.8-mm thick low-alloy DC04 steel sheets were used as test material. The profile tool-path trajectory was generated using the EDGECAM software. The slope angle and diameter of the base of the conical shaped drawpieces were 70°-72° and 65 mm, respectively. The drawpiece heights were up to 75 mm. The full synthetic lubricant 75W85 was used to reduce the frictional resistance. The effect of selected incremental forming parameters on the formability of the DC04 sheet and the susceptibility to crack formation have been analysed and discussed. It was found that the surface roughness of the workpiece is strongly influenced by step depth. By controlling the feed rate, it is possible to prevent failure of the material.