Investigation of the ultrasonic vibration effect in incremental sheet metal forming process

Gulati

J Braz. Soc. Mech. Sci. Eng.

et al. 2019

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 Other Parametersmentioning

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

“…It improved the surface quality and reduced the distortion of parts. Iranian scholar M. Vahdati et al [13], using experiments, proved the effects of ultrasonic vibration (UV) on SPIF in reducing the axial force, springback, and surface roughness. Iranian scholar S. Amini et al [14] applied axial high frequency and low amplitude UV to the forming tool to form a 1050 aluminum straight groove.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Analysis of Single Point Incremental Forming Force with Static Pressure Support and Ultrasonic Vibration

Liu

Yang

et al. 2019

Materials

In order to solve the problem of low accuracy caused by instability and springback during the single point incremental forming (SPIF) process, static pressure support (SPS) and ultrasonic vibration (UV) are introduced into the technology for auxiliary forming. In order to qualitatively and quantitatively study the mechanism of static pressure support–ultrasonic vibration-single point incremental forming (SPS-UV-SPIF) force, a typical truncated cone is used as the research object. The working principle and motion rules of the technology are analyzed. The sheet micro-element of the sidewall area is taken as an analysis object. The spatial stress balance equation of the sheet is constructed. The various stresses are integrated and calculated. The forces in each area of the sheet are analyzed and modeled. Finally, an analytical model for SPS-UV-SPIF force is established. The influence law of the static pressure parameter and the vibration parameter on the forming force is obtained. The corresponding SPS system and UV system are designed. The Kistler forming force test system is built. The experimental results are consistent with the theoretical analysis results, which verifies the correctness of the analytical model.

Journal of Manufacturing Processes

“…This used the principle that at cryogenic temperatures, there is enhanced tensile elongation for certain face centred cubic alloys, resulting in increased strain hardening. Vahdati et al [119] have developed an ultrasonic vibration assisted setup. Tests were carried out on AA 1050-O sheets and their results showed improvement in forces, accuracy and surface finish of the formed parts.…”

Section: Optimized Workpiece Orientationmentioning

confidence: 99%

Single point incremental forming: An assessment of the progress and technology trends from 2005 to 2015

Behera

Sousa

Ingarao

et al. 2017

215

The last decade has seen considerable interest in flexible forming processes. Among the upcoming flexible forming techniques, one that has captured a lot of interest is Single Point Incremental Forming (SPIF), where a flat sheet is incrementally deformed into a desired shape by the action of a tool that follows a defined toolpath conforming to the final part geometry. Research on SPIF in the last ten years has focused on defining the limits of this process, understanding the deformation mechanics and material behavior and extending the process limits using various strategies. This paper captures the developments that have taken place over the last decade in academia and industry to highlight the current state of the art in this field. The use of different hardware platforms, forming mechanics, failure mechanism, estimation of forces, use of toolpath and tooling strategies, development of process planning tools, simulation of the process, aspects of sustainable manufacture and current and future applications are individually tracked to outline the current state of this process and provide a roadmap for future work on this process.