Optimization of relative tool position in accumulative double sided incremental forming using finite element analysis and model bias correction

Ndip-Agbor, Ebot; Smith, Jacob W.; Ren, Huaqing; Jiang, Zhen Ming; Xu, Jingcheng; Moser, Newell; Chen, Wei; Xia, Zhihong; Cao, Jian

doi:10.1007/s12289-014-1209-4

Cited by 16 publications

(10 citation statements)

References 25 publications

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“…The prediction via the simplified model was very close to the experimental results in a certain range of angles and the deviation was controlled within 5 deg. The results show that the combination of the values of D and S is not unique when forming a specific wall angle [29,66]. A similar parametric study was also reported by Ren et al [28] as the tool gap and tool position angle were chosen as parameters.…”

Section: Deformationsupporting

confidence: 66%

“…Toolpath optimization and combination with out-to-in DSIF toolpath are verified to be beneficial for the enhancement of formability and profile accuracy [47]. Other numerical analyses reveal the unique deformation mechanism in ADSIF of enhanced shearing and bending effect in contrast to dominant stretching and bending effect in conventional DSIF processes [7,29]. In summary, the ADSIF is a noteworthy strategy and has a considerable potential of applications.…”

Section: Toolpath Design In Dsifmentioning

confidence: 84%

“…On the other hand, many damage models have been developed based on classic fracture theories, including Gurson-Tvergaard-Needleman model and Lemaitre continuum damage mechanics model to provide an insight in fracture mechanisms [61][62][63][64]. Similar studies are making progress in the DSIF field based on the methods such as FEA [7], parametric research [28,29], or the stress analysis amended from the previous SPIF studies [30]. The clear understanding for the deformation mechanisms in various ISF processes helps to learn the reasons for the disparities and the ways for further improvement of formability and geometry accuracy in SPIF, DSIF, and ADSIF [30].…”

Section: Deformation Mechanisms Of Disfmentioning

confidence: 99%

“…According to the sine law, the sheet thickness decreases and the chance of failure rises when the wall angle increases. Thus, the maximum achievable wall angle α max is regarded as the most important indicator for the formability of the DSIF process and has been widely implemented in a comparative study [24] and a parametric investigation [28,29].…”

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: Deformationsupporting

confidence: 66%

Section: Toolpath Design In Dsifmentioning

confidence: 84%

Section: Deformation Mechanisms Of Disfmentioning

confidence: 99%

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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“…compared with that in single point ISF. Smith et al[120] studied the deformation mechanism in ADSIF by numerical simulation and Ndip-Agbor et al[121] developed an effective strategy for relative tool position optimization in ADSIF. Moser et al[117] developed a new thickness correction model to compensate the tool path of the bottom tool.…”

mentioning

confidence: 99%

Investigation of control strategies for fracture prevention in the multi-point incremental sheet forming process

Wang¹

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This thesis is focused on understanding the deformation and failure mechanisms in incremental sheet forming (ISF) and on development of effective and efficient closed-loop control strategies to delay the fracture in multi-point ISF. Incremental sheet forming is a flexible and energy-efficient rapid prototyping process for production of small-batch and customized functional sheet components. The innovation of ISF is to achieve higher formability, flexibility and process control with localized plastic deformation compared with traditional sheet metal forming processes. Multi-point incremental forming (MPIF) shows higher formability and geometric accuracy than single point incremental forming (SPIF) and has attracted interest from industry currently. In the past decades, the industry application of multi-point ISF is still limited due to the limitation of formability, especially for producing parts with complex geometric features. Experimental and numerical ISF studies show that the formability in ISF can be improved by altering some critical process parameters. However, most of the proposed methodologies are either component specific or are based on trial-and-error approaches, while limited work has been published on closed-loop feedback control strategies for formability improvement in multi-point ISF. The first research objective of this thesis is the deformation mechanism and formability investigation in multi-point ISF. The aim of this study is to identify the contribution of different deformation modes and lay a foundation of developing damage model-coupled numerical simulation for fracture prediction in multi-point ISF. To this end, a full-scale three-dimensional numerical simulation with solid finite elements is developed. The deformation modes in different layers at different contact zones along different directions are investigated and discussed in detail. It is indicated that the existence of the supporting die leads to an increase of the hydrostatic pressure and the through-thethickness shear strain, and a decrease of the stress gradient in the thickness direction in the doublesided contact zone, which may lead to smaller springback and slow the damage accumulation rate in multi-point ISF. The second objective of this thesis is focused on the fracture prediction in multi-point ISF. In particular, six damage models are coded into finite element models through ABAQUS/VUMAT subroutine and a numerical comparative study is conducted for fracture prediction in multi-point ISF with a free-formed ellipsoid shape under different loading conditions. It is indicated that the Ayada model could predict the fracture location and fracture depth more accurately than others, however, it is also found that the fracture location and fracture depth cannot be accurately predicted simultaneously with the investigated damage models in this study. In addition, it can be found that Publications included in this thesis No publications included.

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Energy Reduction in Manufacturing via Incremental Forming and Surface Microtexturing

Cao

Malhotra

2018

Energy Efficient Manufacturing

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Optimization of relative tool position in accumulative double sided incremental forming using finite element analysis and model bias correction

Cited by 16 publications

References 25 publications

Double-Sided Incremental Forming: A Review

Double-Sided Incremental Forming: A Review

Investigation of control strategies for fracture prevention in the multi-point incremental sheet forming process

Energy Reduction in Manufacturing via Incremental Forming and Surface Microtexturing

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