Incremental sheet metal forming - Incremental Single Point

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  • 1. Incremental sheet metal Forming single Point Incremental Forming Metal forming Course Compiled By: HoushangAnsarikajal HassankargarPishbijari HassanYousefinezhadGildeh MS.CStudentsOfManufacturing&Production lecturer: Dr.M.bakhshi BabolIndustrial University www.nit.ac.ir Dec.2012 1/31

2. Contents: 1- Abstract 2- Introduction 3- Methods 4- Characteristics 5- Applications 6- Tools & Equipments 7- Advantages & disadvantages 8- Conclusion 9- Suggestion 10- Research & Developments 11- Acknowledgments 12- References Return 2/31 3. Abstract During the last decade, incremental forming is an innovative processing method which has been strongly investigated. Its potential as a flexible manufacturing method was noticed. Incremental sheet forming is a method , where a spherical numerically controlled tool is used to push the sheet to the desired shape against a simple support tool. keywords: Incremental sheet forming , Die less Forming , Return 3/31 4. Introduction In the manufacturing world of today , the demand of highly customized is increasing every day . Even if the mass production is still used, the small quantity batches are more and more required. The key words of manufacturing are: Flexibility , product customization, Customer Orientation , high quality , low production cost. In sheet metal forming techniques , several evolution has made big steps in the last period of time: Return 4/31 5. Steps in sheet metal forming 1-Conventional Deep Drawing 2-NC control for stamping & bending 3-Hydroforming. 4-Multi-point tools 5-Incremental Sheet forming (ISF) Return 5/31 6. Conventional Deep Drawing Return 6/31 7. CNC control for stamping & bending Return 7/31 8. Hydroforming. Return 8/31 9. Multi-point tools Return 9/31 10. Incremental Sheet forming (ISF) Return 10/31 11. History of ISF Variations of ISF have long been practiced in small workshops and private enterprises , and some early concepts of ISF were patented: 1- In the USA by Roux (1960) and Leszak(1967). 2- Academic research bean in the early 1990 in Japan 3- Recently has attracted increasing interest in Europe and Canada. SPIF & TPIF 4- SPIF of circular and elliptical by Iseki et al (1993) 5- Used FE analysis to strains by Shim and park (2001) 6- Moving back and forth along a straight line by Kim and park (2002) 7- Pyramids formed by SPIF and TPIF byBambach et al (2003) 8- Cone formed byFratini et al(2004) 8- A comprehensive review of the development of the process is given by Jeswiet et al (2005) Return 11/31 12. Method's Return 12/31 13. Method's Spinning Return 13/31 14. Method's Single-point Return 14/31 15. Method's Two-point Return 15/31 16. Method's -> SPIF & TPIF Return 16/31 17. Characteristic's Return 17/31 18. Forming Step & Tool patch Return 18/31 19. Forming Step & Tool patch Return 19/31 20. Applications Return 20/31 21. Applications Return 21/31 22. Forming Parameters Return 22/31 d: Tool diameter t.: Sheet thickness : Tool direction angle S: Spindle rpm f: Federate z: Step movment 23. Tools & equipments Return 23/31 Hexapod machine Forming Tool 24. Return 24/31 Tools & equipments RoBoShaping 25. Advantages & disadvantages Advantages : 1- The advantage of utilizing a conventional CNC milling machine. 2- Increase in materials formability due to the nature of the process. 3- The great flexibility derived from the absence of positive or negative dies. 4- Easley in re-setup of equipment's for part changing. 5- forming forces is too small than Deep Drawing forces. Return 25/31 26. Advantages & disadvantages Disadvantages: 1- Spring Back. 2- Sheet fracture under Tool 3- deformation and Un-like form Pressure and friction. 4- forming time is too large than deep drawing time. 5- In negative forming ,its difficult to form sharp corner & edge because crack easily occur. 6- Deformation and Un-Like form sometimes occur. Return 26/31 27. Conclusion 1- Increase in sheet thickness Increase in strain Increase in formability. 2- Increase in Tool diameter decrease in stress decrease in formability. 3- Increase in Tool Federate Increase in stress decrease in formability. 4- Increase in Tool speed Increase in heat Increase in formability. Return 27/31 28. Return 28/31 Suggestions With discussed characteristic's and flexibility of ISF(SPIF & TPIF) We suggestions to provide research for following further application : 1-Use of ISF to forming thermoplastics sheet. 2- Use of ISF to car body smoothing. 3- Deliberation of pre-heat effect on formability. 29. Return 29/31 Research & Developments Macro Incremental Forming the main focus of our work has been on application-oriented research and development in the field of production technology for the automotive and mechanical engineering sectors. 30. Acknowledgments With special thanks to: Professors of Metal forming - Babol Industrial University Return 30/31 31. References 1- Jong-Jin park , Yung-ho Kim, Fundamental studies on incremental sheet metal forming technique , Journal of Materials processing Technology 140 (2003) 447-453. 2- Incremental sheet metal forming : a die less rapid prototyping process for sheet metal , IMRC (manufacturing Process and systems Research project), University of BATH. 3- Crina Radu , Effect of process parameters on the quality of parts processed by single point incremental forming, International journal of modern manufacturing technologeis , vol.III.No.2/2011. 4- Alexandru C.FILIP , Ion NEAGOE,An overview on incremental sheet forming , a method for rapid manufacturing of hollow metal parts", Academic journal of manufacturing engineering , vol.8,issue 3/2010. 5- M Skjoedt , M B Silva , P A F martins , N Bay , strategies and limits in multi-stage single-point incremental forming", technical university of Denmark, department of mechanical engineering, kongens lyngby, Denmark, strain Analysis vol.45. 6-W.C.Emmens , D.H.Van , A.H.Van, The FLC , enhanced formability , and incremental sheet forming,International Deep drawing research group.IDDRG 2009 int.Conference.Golden.Co.USA. 7- A.petek,K.kuzman,J.Kopac,Deformation and forces analysis of single point incremental sheet metal forming,International scintific journal , vol.35.issue 2.feb 2009. 8- Kathryn jackson,Julian Allwood ,The mechanics of incremental sheet forming,Department of engineering,University of cambridge,Journal of materials processing technology 209(2009,1158-1174) 9- NCME20101391. 10- ICME 2010 1388. 11- 1388 Return 31/31

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