Search results for "Forming processes"
showing 10 items of 73 documents
Innovative sheet metal forming processes: numerical simulations and experimental tests
2004
Abstract In this paper, computer aided engineering of some innovative sheet metal forming processes is reviewed. In particular, tube hydroforming processes and spinning processes are examined. Advanced numerical tools are utilized with the aim to design proper forming operations able to produce sound components. Furthermore, as far as the spinning process is concerned, experimental verifications are carried out to confirm the effectiveness of the numerical predictions.
Determination of Technological Forces in the Incremental Forming Process
2013
The paper presents a joint theoretical and experimental approach to determine the technological forces within the asymmetric single point incremental forming ASPIF process, based upon a theoretical model, image processing and data acquisition. The first step of this approach was to develop a theoretical model of the forces within the process, based upon the model of a mechanical feed drive of a CNC milling machine. By means of this model, relationships between the resistant torque at the motor spindle level and the technological force on the movement axis could be determined. Using an image processing method, which allowed the user to extract information within the machines operator panel a…
Sheet Thinning Prediction in Single Point Incremental Forming
2005
Incremental forming processes are characterized by a well known and particular feature: any deformation across the sheet plane determines sheet thinning, since the blank is fully clamped by means of a proper equipment. As a consequence, the availability of effective and reliable CAE tools capable to supply an accurate prediction of sheet thinning as a function of process parameters, represents a strong requirement for a wider practical application of incremental forming. The already available theoretical models (i.e. the sine law) do not provide, on the other hand, satisfactory results. Therefore in the paper a couple of numerical analysis strategies was applied to simulate simple increment…
An exploratory study for analyzing the energy savings obtainable by reshaping processes of sheet metal based components
2017
Abstract Producing materials causes about 25% of all anthropogenic CO2 emissions. Reshaping could be one of the most efficient strategy to foster material reuse and lower the environmental impact due to material production. Sheet metal forming processes can be applied to reshape sheet metal based component. This research field is still almost unexplored and the actual environmental impact saving potential has not been quantified. The present paper aims at starting to cover this research gap, a modeling effort to quantify the environmental impact saving of reshaping is proposed. Primary energy demand for conventional recycling and reshaping are quantified and compared. Primary energy savings…
On the Sustainability Evaluation in Sheet Metal Forming Processes
2011
In sheet metal forming processes there is still a lack of knowledge in the field of environmental sustainability mainly due to the need of a proper modeling of issues and factors to be taken into account. Such topic is, nowadays, a urgent and remarkable issue in manufacturing and the main concerns are related to more efficient use of materials and energy. What is more, the estimation of environmental burdens of forming technologies is very complex to be accomplished since it is essentially process-dependent. This means that when comparing, for instance, a traditional forming process with an innovative one, there are some peculiar aspects to be considered; actually, processes can be rather d…
A force measuring based strategy for failure prevention in incremental forming
2006
Abstract Incremental forming processes show a number of advantages compared to the traditional processes but, at the same time, some drawbacks are clearly known. Current problems, include the slowness of the process, low accuracy and a lack of knowledge in the field of material formability. This paper is focused on the latter issue: an industrially oriented methodology for detecting the approach of failure in incremental forming is proposed. The approach is based on the analysis of the trend of the forming force in order to assess whether the process can be run safely. If not, a proper strategy, to avoid material failure, is proposed and experimentally validated.
A sustainability point of view on sheet metal forming operations: material wasting and energy consumption in incremental forming and stamping process…
2012
Abstract Sustainability and sustainable production is nowadays a wide research field due the urgency of reducing environmental burdens of industrial production. Sustainable manufacturing issues are widely investigated too. In particular, due to the relevance such issues assume for automotive and aeronautical industry, the investigation of sheet metal forming processes sustainability is worth studying and, within this research fields, a certain lack of knowledge is still present. Many studies have been presented concerning the evaluation and reduction of environmental burdens in manufacturing. In this paper, the authors focus on sheet metal forming and aim to investigate both the efficient u…
Sustainability issues in sheet metal forming processes: an overview
2011
Abstract Environmental sustainability in manufacturing is nowadays an urgent and remarkable issue and the main concerns are related to more efficient use of materials and energy. In sheet metal forming processes there is still a lack of knowledge in this field mainly due to the need of a proper modelling of sustainability issues and factors to be taken into account. The aim of this paper is mainly to underline the state of the art from a forming point of view about the sustainability contributions offered in any phase of a product life cycle. Actually, a lack in terms of comprehensive contributions is present in the technical literature, thus, the authors try to give a sort of holistic visi…
Design of complex sheet metal forming processes: a new computer aided progressive approach
2010
The growing interest in sheet metal stamping processes, particularly in automotive industry, led to three main issues in this field: request of very complex shapes; growing interest in springback control; solution of multi-objective problems. This makes the design of the sheet metal stamping processes very difficult, since the number of both design variables and design objectives are progressively increased; therefore, proper design methodologies to reduce times and costs are highly required. In this paper, an innovative design approach able to manage and optimize complex stamping operations is proposed. In particular, a progressive design approach based on the integration between numerical…
Shape Distortion and Thickness Distribution during SPIF Processes: Expermental and Numerical Analysis
2011
Single Point Incremental Forming (SPIF) is a quite new sheet forming process which offers the possibility to deform complex parts without dedicated dies using only a single point tool and a standard 3-axis CNC machine. The process mechanics enables strains much higher than traditional sheet forming processes, but particular attention must be given to the final part geometrical accuracy. In this paper the capabilities of a dedicated explicit numerical model are quantitatively analyzed on pyramid-shaped parts. In particular a comparison between experimental and numerical results is reported. Three different shapes at the varying of the stamping angle were considered and the final shape was ac…