Search results for "sheet forming"

Re-forming end-of-life components through single point incremental forming

2020

Abstract Applying Circular Economy strategies is mandatory to face material demand while minimizing the environmental impact. Manufacturing processes are to be thought as means to enable material/component reuse strategies. This paper presents the suitability of Single Point Incremental Forming (SPIF) to re-form End-of-life sheet metal components. Deep drawing followed by SPIF process on aluminium alloys were carried out to simulate reforming processes chain. The resulting thinning and strain distributions were experimentally analysed for different configurations. The research proves that the local action and enhanced formability nature of SPIF allow non-homogeneously thinned and reduced fo…

Magnetic field-assisted single-point incremental forming with a magnet ball tool

2021

Abstract This paper describes magnetic field-assisted single-point incremental forming (M-SPIF) with a Nd-Fe-B magnet ball tool. In M-SPIF, the tool driven by magnetic force plastically deforms a sheet. The polarity of the magnet tool helps to make the magnetic force (i.e., forming force) more controllable. In creating a truncated cone, the direction of the magnetic force gradually points more outward as the process progresses, and material is forced outwards from the cone center, increasing thinning in M-SPIF, while the cone center remains undeformed in traditional SPIF. Moreover, M-SPIF creates less localized plastic strain than traditional SPIF while forming the desired geometry.

ROUGHNESS CONTROL OF PARTS OBTAINED THROUGH INCREMENTAL SHEET FORMING

2007

Abstract The present paper adresses the issue of controlling the quality of surface in the case of a new sheet metal forming process by which various curved shells are formed without the help of expensive dies. The roughness of the surface which comes in direct contact with the punch at incremental sheet forming suffers an obvious worsening compared to the initial blank surface roughness. The present paper discusses the measuring of the roughness of parts obtained through the previously mentioned process and highlights the factors that influence it. There were taken into account the initial roughness of the punch, the punch diameter and the friction coefficient between the punch and the bla…

Method for Manufacturing Custom-Shaped Prosthetic Parts from Titanium Alloys by Incremental Forming Using Industrial Robots

2014

The last decade has shown an increasing interest in a new class of forming processes known as Incremental Sheet forming (ISF). A possible application for this new procedure, targeted by the authors of this paper, is the manufacturing of custom-shaped prosthetic parts for use in various areas of human medicine. Such prostheses can have a functional role, when they target the replacing of a functional component of the human body, or an esthetic role, when they target the solving of problems related to the appearance of the human body. In this paper the authors aim to determine the strain hardening curves for the titanium alloy Ti6Al4V at room temperature and at 800°C. The incremental forming …

An analytical model for improving precision in single point incremental forming

2007

Abstract In the modern manufacturing scenario and, in particular, in sheet metal forming, the requirement of customised production is still growing. The introduction of incremental forming enables the production of customised components in small lots. In particular, single point incremental forming is characterised by the simplest equipment; any die, in fact, is avoided reducing the necessary tooling to a simple frame, able to clamp the sheet, and a hemispherical punch that imposes the required deformation. This tooling simplicity and the associated process mechanics, in turn, determine a sometimes relevant lack of accuracy. The paper is focused on the investigation of the influence of the …

Shape and dimensional accuracy in Single Point Incremental Forming: State of the art and future trends

2007

Abstract The paper is aimed to discuss some relevant issues concerning an innovative sheet metal forming technology, namely Single Point Incremental Forming. The advantages of this technology are addressed, including its capability to provide effective answers to some impellent industrial requirements: process flexibility, strong customer orientation, production of highly differentiated goods at low industrial costs. As well some relevant drawbacks are highlighted, mainly as concerns the level of accuracy permitted by the process. A wide recognition of the research efforts in this field is presented, taking into account some general considerations on the difference sources of shape and dime…

Robot-based incremental sheet forming – the tool path planning

2021

Abstract To achieve a 3D shape with certain degree of complexity from metal sheets that are flat in the beginning, especially for prototype development or small series production, that is also cost efficient by avoiding high-end dies or expensive tooling, the incremental sheet forming process can represent the ideal choice due to its flexibility, reduced forming forces and increased formability. The process is performed with a round tool that follows a predefined path to deform the flat metal sheet into its final shape. The proper selection of the toolpaths affects the productivity and the accuracy of each part. The process having to focus on forming each single point in increments. For cos…

Recent advances in sheet metal single point incremental forming and friction stir welding

2011

Energy efficiency analysis in Incremental Sheet Forming operations

2012

In literature, manufacturing processes have been studied with different approaches, but a lack in terms of their environmental impact and energy required is still present. The aim of this paper is to compute some energy efficiency analysis on a specific manufacturing process. More in detail, the attention will be focused on the Incremental Sheet Forming process in order to evaluate the required energy and how it changes for changing process conditions. Accordingly, a wide experimental investigation has been executed taking into account different process parameters (i.e. tool depth step, punch diameter, wall inclination angle and sheet thickness). The total energy consumption has been monito…

Development of Magnetic Field-Assisted Single-Point Incremental Forming

2021

Single Point Incremental Forming (SPIF) has recently introduced the concept of material formability enhancement through localized deformation. Since material is processed by means of a pin tool attached to spindle, physical interference (especially in vertical direction) limits attainable shapes with the conventional process. The aim of the following work is to increase the variety of achievable geometries with SPIF through in-process magnetic field assistance. An innovative configuration managing SPIF tool movement using magnetic force is proposed. With this in mind, a magnet configuration was designed to generate a vertical load able to plastically deform a 0.5 mm thick AA1100 aluminum sh…