Prediction of forming forces in single point incremental forming

Bansal, Ankush; Lingam, Rakesh; Yadav, Sateesh Kumar; Reddy, N. Venkata

doi:10.1016/j.jmapro.2017.04.016

Cited by 77 publications

(44 citation statements)

References 18 publications

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“…Min et al (2018) tried to improve the poor geometric accuracy of workpieces plagues in single-point incremental forming (SPIF) due to lack of support and unwanted plastic deformation. Bansal et al (2017) tried to improve geometric accuracy, accurate prediction of sheet thickness, tool-sheet contact area and forming forces are important. Thyssen et al (2017) presented approach as well as first experimental results to compensate inaccuracies in incremental sheet forming caused by local heating.…”

Section: Introductionmentioning

confidence: 99%

Experimental and analytical evaluation of Incremental Sheet Hydro-Forming strategies to produce high forming angle sheets

Kumar

2019

Heliyon

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Incremental Sheet Hydro-Forming (ISHF) is a hybrid process of Incremental Sheet Forming (ISF) and Sheet Hydro-Forming (SHF). In the ISHF process, a single ball tool moves over one side of the surface of the sheet and hydraulic support is provided in another by using the pressurized hydraulic fluid. In the current research, an attempt has been made to achieve high forming angles using ISHF. The forming strategy, multi-stage & multi-step (MSMS), has been proposed to improve the formability in ISHF. The MSMS has resulted in the improvement in the formability and forming angle achieved is . The primary issue, identified in MSMS forming strategy, is the failure of the product due to thinning of the sheet. To address the failure of the sheet due to thinning, a modified version of MSMS was proposed. This modified version of MSMS has shown tremendous improvement in the formability of the ISHF. The forming angle upto has been successfully achieved using the modified version of MSMS. Analytical models have been developed for MSMS forming strategy and for the modified version of MSMS forming strategy. The experimental results are closely the same as predicted by analytical models.

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Section: Introductionmentioning

confidence: 99%

Experimental and analytical evaluation of Incremental Sheet Hydro-Forming strategies to produce high forming angle sheets

Kumar

2019

Heliyon

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“…Regarding the force approaches for metals, analytical models define relations between process parameters, material mechanical properties and force. For example, Bansal et al [ 9 ] relates the forming forces with thickness, meridional and circumferential stresses, contact surface and thickness. Besides experimental models, such as the regression equation as defined by Aerens et al [ 10 ], estimate the forming force by means of experimental data.…”

Section: Introductionmentioning

confidence: 99%

Force Prediction for Incremental Forming of Polymer Sheets

2018

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Incremental sheet forming (ISF) is gaining attention as a low cost prototyping and small batch production solution to obtain 3D components. In ISF, the forming force is key to define an adequate setup, avoiding damage and reducing wear, as well as to determine the energy consumption and the final shape of the part. Although there are several analytical, experimental and numerical approaches to estimate the axial forming force for metal sheets, further efforts must be done to extend the study to polymers. This work presents two procedures for predicting axial force in Single Point Incremental Forming (SPIF) of polymer sheets. Particularly, a numerical model based on the Finite Element Model (FEM), which considers a hyperelastic-plastic constitutive equation, and a simple semi-analytical model that extends the known specific energy concept used in machining. A set of experimental tests was used to validate the numerical model, and to determine the specific energy for two polymer sheets of polycarbonate (PC) and polyvinyl chloride (PVC). The approaches provide results in good agreement with additional real examples. Moreover, the numerical model is useful for accurately predicting temperature and thickness.

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“…Additionally, the axial force in the forming process was analyzed. Ankush et al [21] proposed a predictive model for the forming force in SPIF. e prediction results were compared with the experimental results.…”

Section: Introductionmentioning

confidence: 99%

Influences of Process Parameters and Vibration Parameters on the Forming Force in the Ultrasonic‐Assisted Incremental Forming Process

Bai

Yang

et al. 2018

Advances in Materials Science and Engineering

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In the field of plastic forming, ultrasonic vibration has the advantages of small forming force and high forming quality, and it has been introduced into a single-point incremental plastic forming technique with high flexibility and high precision. The ultrasonic vibration single-point incremental compound forming technology with all the above advantages has been achieved. To reveal the variation tendency of the forming force under ultrasonic vibration and single-point incremental coupling, the process parameters (layer spacing, tool head radius, and feed rate) and vibration parameters (frequency and amplitude) on the forming force of the composite technology were quantitatively analyzed by theory, simulation, and experiment. The simulation and experimental results showed that ultrasonic vibration can significantly reduce the forming force of the composite technology. Compared with the simulation results, the theoretical results are not only closer to the experimental results but also have a shorter computation time and better prediction effect on the forming force. The change in the process parameters has a linear effect on the forming force, the nonlinearity of the vibratory parameters influences the forming force, and the frequencies and amplitudes in a suitable range allow the forming force to reach a minimum value. These conclusions have some significance for further studies on the ultrasonic vibratory single-point incremental composite forming technology.

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Prediction of forming forces in single point incremental forming

Cited by 77 publications

References 18 publications

Experimental and analytical evaluation of Incremental Sheet Hydro-Forming strategies to produce high forming angle sheets

Experimental and analytical evaluation of Incremental Sheet Hydro-Forming strategies to produce high forming angle sheets

Force Prediction for Incremental Forming of Polymer Sheets

Influences of Process Parameters and Vibration Parameters on the Forming Force in the Ultrasonic‐Assisted Incremental Forming Process

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