Reduction of geometric deviation by multi-pass incremental forming combined with tool path compensation for non-axisymmetric aluminum alloy component with stepped feature

Dai, Peng; Chang, Zhidong; Meng, Liang

doi:10.1007/s00170-018-3194-0

Cited by 21 publications

(12 citation statements)

References 19 publications

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“…However, producing parts with satisfactory accuracy is still challenging because geometric errors may arise from multiple sources, including machine compliance, motion inaccuracy, and in-process and post-process springback. Feedforward toolpath optimization [26,27], feedback toolpath compensation [28,29], in-process annealing [30], and post-process annealing [31] are some of the main strategies employed to solve this problem.…”

Section: Architectural and Constructionmentioning

confidence: 99%

Toolpath Planning for Manufacturing of Complex Parts Through Incremental Sheet Forming

Jiang

Liao

Slocum

et al. 2022

ASME Open Journal of Engineering

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Incremental sheet forming (ISF) offers great flexibility in producing complex sheet parts as compared with conventional sheet forming processes where part-specific die sets are required to form a product. While there are many potential applications of ISF in various industries, toolpath planning for multifeature parts remains a leading challenge hindering the wide adoption of ISF. In this study, a criterion based on the gradient of the target surface was established for determining the appropriate feature forming sequence. Based on the analysis of the gradients of the surface, multifeature geometries were separated into two categories: “plane-referenced” and “surface-referenced.” Experimental investigations of forming a multifeature air intake as an example were carried out to demonstrate the proposed criterion and feature forming sequence. The results show that the choice of the optimal sequence depends on the type of geometry formed. The proposed criterion extends existing toolpath strategies for relatively regular geometries, where features are formed from flat or inclined bases to more complex geometries with features on a curved basis. This work will be of interest to both design and manufacturing communities.

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Section: Architectural and Constructionmentioning

confidence: 99%

Toolpath Planning for Manufacturing of Complex Parts Through Incremental Sheet Forming

Jiang

Liao

Slocum

et al. 2022

ASME Open Journal of Engineering

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“…Nowadays, double-pass or multiple-pass forming are common strategies proved to be useful in improving part dimensional accuracy in incremental forming. For instance, Dai et al [12] implemented a multipass strategy to deform non-axisymmetric parts manufactured from aluminum alloy and compared to single pass forming, they succeeded to improve part accuracy by more than 60%. CAM software systems offer multiple solutions similar to those used in milling that can be successfully implemented also for the toolpath in SPIF processes.…”

Section: Introductionmentioning

confidence: 99%

Achieving Accuracy Improvements for Single-Point Incremental Forming Process Using a Circumferential Hammering Tool

Nasulea

Oancea

2021

Metals

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The paper presents a novel solution for improving the accuracy of the wall area of parts manufactured by single point incremental forming. Thus, a forming tool with a special design that works according to the principle of circumferential hammering is deployed, with a direct improving effect of the forming conditions and consequently of the dimensional accuracy of the part. The research is focused on an experimental study of frustum-of-cone shapes manufactured from sheet metal blanks of DC05 deep drawing steel of 1 mm thickness. A typical customary technological setup is used for the single point incremental forming process, without any additional elements, and two forming tools, a hemispherical and a special one, which use the circumferential hammering effect. Several preliminary tests using both tools were performed in order to prove that part accuracy can be significantly improved by using the circumferential hammering tool. The research was further expanded to investigate the influence on part wall dimensional accuracy of three factors: tool spindle speed, tool feed rate and part dimensional configuration. Using a full factorial plan of experiments the results of 32 test runs were processed. All parts were machined adequately, free of any material fracturing. Based on the achieved machining accuracy of the part walls, precision mathematical models were developed for the prediction of part dimensional accuracy in those areas. The mathematical models were validated by practice, as the predicted accuracies were matched by the experimental results.

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“…Nirala [8] proposed an effective multi-stage forming strategy to eliminate the sinking phenomenon and discussed the number of intermediate forming stages required by avoiding the overlapping forming of the sheet metal. Dai et al [14] studied the multi-stage forming of sheet metal parts with a non-axisymmetric complex cross section by using the compensated intermediate forming stage toolpath so as to improve the geometric accuracy. Zhao and Meehan [15] studied the wrinkling deformation mechanism that occurred between two adjacent stages in multi-stage forming, which helps to optimize the deformation stages to eliminate the unnecessary wrinkling phenomenon.…”

Section: Introductionmentioning

confidence: 99%

Toolpath Planning and Generation for Multi-Stage Incremental Forming Based on Stretching Angle

2021

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To solve the problems that exist in the multi-stage forming of the straight wall parts, such as the sheet fracture, uneven thickness distribution, and the stepped feature sinking, a new forming toolpath planning and generation method for the multi-stage incremental forming was proposed based on the stretching angle. In this method, the parallel planes that were used for forming toolpath generation were constructed by using the stretching angle so that the distances between the parallel planes and the forming angles were gradually reduced. This makes the sheet material flow become changed and the thickness thinning is relieved. The software system for the toolpath generation was developed by using C++, VC++, and OpenGL library. In order to verify the feasibility of the proposed method, numerical simulation and forming experiments were carried out for the single stage forming, the traditional multi-stage forming, and multi-stage forming based on the proposed forming toolpath, using 1060 aluminum sheets. The comparative analysis of the thickness distribution, profile curve, strain curve, and sheet material flow shows that the proposed method is feasible, and the profile dimension accuracy is better, the thickness distribution is more uniform, and the sinking and bulging are significantly reduced. The formed sheet part with the stretching angle of 15° has higher dimensional accuracy, smaller bottom subsidence, and larger thickness than that of the stretching angle 5°.

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Reduction of geometric deviation by multi-pass incremental forming combined with tool path compensation for non-axisymmetric aluminum alloy component with stepped feature

Cited by 21 publications

References 19 publications

Toolpath Planning for Manufacturing of Complex Parts Through Incremental Sheet Forming

Toolpath Planning for Manufacturing of Complex Parts Through Incremental Sheet Forming

Achieving Accuracy Improvements for Single-Point Incremental Forming Process Using a Circumferential Hammering Tool

Toolpath Planning and Generation for Multi-Stage Incremental Forming Based on Stretching Angle

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