Process capabilities of commercially pure titanium grade 2 formed through warm incremental sheet forming

Kumar, Pavan; Tandon, Puneet

doi:10.1177/0954405421995669

Cited by 11 publications

(6 citation statements)

References 33 publications

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“…This implies that the conical objects are subjected to the plane strain condition during forming. The same observations are also reported in the literature [29,30].…”

Section: Forming Limit Diagramsupporting

confidence: 89%

A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

Shahare

Dubey

Kumar

et al. 2021

Metals

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Incremental Sheet Forming (ISF) is emerging as one of the popular dieless forming processes for the small-sized batch production of sheet metal components. However, the parts formed by the ISF process suffer from poor surface finish, geometric inaccuracy, and non-uniform thinning, which leads to poor part characteristics. Hammering, on the other hand, plays an important role in relieving residual stresses, and thus enhances the material properties through a change in grain structure. A few studies based on shot peening, one of the types of hammering operation, revealed that shot peening can produce nanostructure surfaces with different characteristics. This paper introduces a novel process, named the Incremental Sheet Hammering (ISH) process, i.e., integration of incremental sheet forming (ISF) process and hammering to improve the efficacy of the ISF process. Controlled hammering in the ISF process causes an alternating motion at the tool-sheet interface in the local deformation zone. This motion leads to enhanced material flow and subsequent improvement in the surface finish. Typical toolpath strategies are incorporated to impart the tool movement. The mechanics of the process is further explored through explicit-dynamic numerical models and experimental investigations on 1 mm thick AA1050 sheets. The varying wall angle truncated cone (VWATC) and constant wall angle truncated cone (CWATC) test geometries are identified to compare the ISF and ISH processes. The results indicate that the formability is improved in terms of wall angle, forming depth and forming limits. Further, ISF and ISH processes are compared based on the numerical and experimental results. The indicative statistical analysis is performed which shows that the ISH process would lead to an overall 10.99% improvement in the quality of the parts primarily in the surface finish and forming forces.

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“…This implies that the conical objects are subjected to the plane strain condition during forming. The same observations are also reported in the literature [29,30].…”

Section: Forming Limit Diagramsupporting

confidence: 89%

A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

Shahare

Dubey

Kumar

et al. 2021

Metals

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“…6 A few researchers have explored ISF for producing components with hard to form alloys but such works are rare. [7][8][9][10] However, ISF of Extra Deep Drawn (EDD) steel, one of the most important alloys used in the automobile industry is rarely discussed in the literature. EDD steel is used in applications where large strain deformation is required.…”

Section: Introductionmentioning

confidence: 99%

Investigating the incremental forming capabilities of extra deep drawn steel

Kumar

Priyadarshi

Tandon

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Incremental Sheet Forming (ISF) is a sheet metal forming process, which relies on minimum part-specific tooling. Extra Deep Drawn (EDD) steel has been used for making door inners, dash panels, bodyside inners, etc. due to its good weldability and relatively low yield strength. However, to date very limited work is reported on ISF of EDD steel. Besides, no work, which exhaustively discusses the practicability of EDD steel for effectual incremental forming of components, is found to be reported. The present work discusses the ISF of EDD steel sheets and examines the limitations of ISF in forming the parts out of 1.0 mm thick EDD steel sheets. Two geometries, i.e., ellipsoidal cone (with varying wall angle) and truncated cone (with constant wall angle) were used as test cases to evaluate the formability of EDD steel sheets, in terms of Critical Wall Angle (CWA). Further, the formability of EDD steel with ISF is evaluated using both strain-based and stress-based forming limit curves. The thickness distribution, geometrical accuracy, forming forces, and surface roughness and hardness are evaluated in the formed components. The work, through numerical simulations and experimental analyses, investigates the process capabilities of ISF to form the EDD steel sheets in terms of formability, thickness distribution, geometrical accuracy, forming forces, and surface roughness and hardness to ascertain the scope of the proposed process.

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“…Singh et al 18 performed the experiments of ISF and ET-ISF on the AA1050 sheet metal and revealed the minimum sheet thickness values after the deformation, which is close to the findings of this research work. Forming force (Fz) in the case of Titanium Grade 2 can be validated with the experimental work carried out by Kumar et al 29…”

Section: Resultsmentioning

confidence: 57%

“…In this research, global heating of the sheets was done during the finite element simulations of the ET-ISF process which can be done with the help of halogen lamps during experiments. 29 The schematic diagram of ET-ISF is shown in Figure 1(b). The mode of heat transfer during ET-ISF can be understood by Figure 1(c).…”

Section: Elevated Temperature Incremental Sheet Forming (Et-isf)mentioning

confidence: 99%

Numerical analysis of the effects of ultrasonic vibrations and elevated temperature in incremental sheet forming

Sharma

Gupta

Tandon

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Incremental sheet forming (ISF) is one of the novel processes practised for more than the last decade in the field of sheet metal forming. ISF, although recognised as a promising manufacturing process over conventional forming, does not give good results in terms of geometrical accuracy, sheet thinning, surface finish and the forming forces. To make the ISF process more efficient, strategies to enhance the forming limits and capabilities are constantly being developed. Two such adaptations to the ISF process are ultrasonic vibration-assisted incremental sheet forming (UVaISF) and elevated temperature incremental sheet forming (ET-ISF). In the present work, investigations have been carried out to compare ISF, UVaISF and ET-ISF on 1 mm thick AA1050 and Titanium Grade 2 sheets with the help of numerical simulations using Abaqus/CAE. Response parameters like stress, strain, thickness distribution, the final shape of the geometry, strain energy, energy dissipated during plastic deformation and the forming forces are evaluated to measure the effectiveness of the processes. It is observed that there is a considerable reduction in the forming forces and spring-back with the UVaISF and ET-ISF processes, in comparison to the ISF at room temperature. This considerable reduction in the forming forces and spring-back is due to the softening behaviour of sheet material and the drop in yield strength during UVaISF and ET-ISF processes. The work overcomes some of the limitations of the ISF process and enlarges the scope of application of the process.

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Process capabilities of commercially pure titanium grade 2 formed through warm incremental sheet forming

Cited by 11 publications

References 33 publications

A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

Investigating the incremental forming capabilities of extra deep drawn steel

Numerical analysis of the effects of ultrasonic vibrations and elevated temperature in incremental sheet forming

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