Optimization Study on Incremental Forming of Sheet Metal AA5052 for Variable Wall Angle using CNC Milling Machine

Pandivelan, C.; Jeevanantham, A.K.; Sathiyanarayanan, C.

doi:10.1016/j.matpr.2018.02.267

Cited by 13 publications

(5 citation statements)

References 10 publications

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“…However, the FLD is obtained for two-layer samples under biaxial strain conditions (Figure 13b). The reasons for this change in the strain conditions for the two-layer samples compared to the base sheet can be attributed to the work of hardening and the high strain rate on the two-layer samples in the explosive welding and the rolling process, which causes a higher thinning rate of the two-layer samples under SPIF process [30]. Figure 13c is the FLD obtained to study the influence of the arrangement of the two-layer sample with a pyramid geometry.…”

Section: Incremental Forming Resultsmentioning

confidence: 99%

Experimental and Numerical Investigation of Forming Limit Diagrams during Single Point Incremental Forming for Al/Cu Bimetallic Sheets

Tayebi,

Nasirin,

Akbari

et al. 2024

Metals

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This article investigated the formability of aluminum/copper bimetal sheets during single-point incremental forming. First, the two-layer sheets were produced by the explosive welding process; then, the rolling process was performed with 50% strain on two-layer samples. Considering the importance of examining the mechanical and metallurgical properties on the formability of the two-layer samples, the mechanical properties were first examined, including the uniaxial tensile and micro-hardness tests. Then, metallurgical tests were performed, including scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy (SEM-EDX) to investigate the fracture surface and penetration depth and an X-ray diffraction (XRD) test to check the secondary phase particles in the penetration zone of Al and Cu in five different annealing temperature conditions. Considering that the forming limit diagram (FLD) is dependent on the strain path, to study the effect of the strain path, the two-layer samples were formed by three geometries: pyramid, cone, and straight groove. Simulations of FLD by Abaqus software 6.14-4 with four different methods were studied: FLDCRT, effective strain rate (ESR), second derivation of thinning (SDT), and maximum strain rate (MSR). The results showed that the FLDCRT criterion provided a more accurate estimate of the necking time. In the following, the values of the thickness distribution were carried out by experimental and numerical methods, and the results between the methods were in good agreement.

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Section: Incremental Forming Resultsmentioning

confidence: 99%

Experimental and Numerical Investigation of Forming Limit Diagrams during Single Point Incremental Forming for Al/Cu Bimetallic Sheets

Tayebi,

Nasirin,

Akbari

et al. 2024

Metals

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“…Furthermore, an accurate description of the forming forces is of great importance for the proper selection of the equipment to be used, since several incremental forming processes are performed with machines that are not specially dedicated to this technology. Several pieces of research were carried out using five-axes machining centers [56,[84][85][86][87] (Figure 5a); however, in recent years, the use of robot arms is increasing due to the implementation of advanced SPIF technologies such as double-sided incremental forming [88][89][90] (Figure 5b). The incremental forming process does not load these machines in the same way as the processes that these machines were originally designed for.…”

Section: Forming Forcesmentioning

confidence: 99%

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Trzepieciński

Oleksik

Pepelnjak

et al. 2021

Metals

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Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

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“…ANOVA (analysis of variance) was used to determine which parameter was statistically significant to residual tensile strength [12]. Pandivelan et al used the Taguchi L9 orthogonal array to identify the best combination of parameters to increase the formability of the wall angle test [13].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Double Hole Composite Plate on the Floater Compartment of Amphibious Aircraft Using Taguchi Method

Nurrohmad,

Antares,

Nuranto

et al. 2024

war. ardhia

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A floater or pontoon is one of the most important components of amphibious aircraft to assist the take-off and landing operation. The inner structure of the floater consists of compartments to carry some payload and to reinforce the structural strength due to water and aerodynamic load that occurred during the aircraft operation. The composite material is chosen instead of metal to reduce the weight of the floater. One of the problems on the composite panel is the existence of some holes due to joint with another part or also to minimize its weight. In this study, the optimization of the composite plate with the existence of a double hole is done using the Taguchi Method. The objective of this optimization is to minimize the stress that happens due to the tensile load. The Finite Element Method is used to calculate the maximum stress and stress distribution on the plate. Tsai-Hill failure criterion is used to make sure that the optimum design does not fail. This optimization considers open hole configuration, the ratio between diameter, and hole distance, as well as the fiber orientation as the control factors. The Taguchi L9 Orthogonal Array is used to make 9 design variations from 3 control factors and 3 levels. This process also considers the thickness of the lamina and material strength as noise factors. The optimization process results in the optimum composite design as follows: 1st double hole configuration (in line with the load direction), the ratio between diameter and hole distance is 0.5, and the fiber direction is [0/90/45/-45]s. The maximum in-plane stress of the optimum design is 39.56 MPa with the Tsai-Hill value is 0.23, so the design does not fail. This optimum configuration of the composite plate can be used to make design considerations for an amphibious aircraft floater compartment.

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Optimization Study on Incremental Forming of Sheet Metal AA5052 for Variable Wall Angle using CNC Milling Machine

Cited by 13 publications

References 10 publications

Experimental and Numerical Investigation of Forming Limit Diagrams during Single Point Incremental Forming for Al/Cu Bimetallic Sheets

Experimental and Numerical Investigation of Forming Limit Diagrams during Single Point Incremental Forming for Al/Cu Bimetallic Sheets

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Optimization of Double Hole Composite Plate on the Floater Compartment of Amphibious Aircraft Using Taguchi Method

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