A Process/Machine coupling approach: Application to Robotized Incremental Sheet Forming

Gulati

J Braz. Soc. Mech. Sci. Eng.

et al. 2019

Incremental sheet forming (ISF) significantly exempts use of expensive dies and reduces tooling cost for manufacturing complex parts in the field of sheet metal forming which makes it suitable for manufacturing prototypes and low volume production as compared to other traditional sheet metal forming processes. ISF also finds suitability for producing components of old machinery, which are otherwise very difficult to form due to the unavailability of forming dies. Moreover, the incremental nature of the process and local deformation of the sheet ensures higher formability and lower required forming force. To take advantages of lower required forming force, it is important to minimize and estimate forming force through the manipulation of the parameters for the safe utilization of hardware. In this review article, a literature survey was carried out quantitatively to study different aspects of ISF, especially to show different process parameters and techniques that affect the forming forces significantly. The current state of the art of the ISF process has been discussed with detailed analysis of process capabilities and limitations in terms of forming forces. Influences of different process parameters and forming techniques have also been studied on forming forces. Some parameters have shown their significance to control the forming force in order to preserve forming machinery. A lack of focus was found on effects of some important forming process parameters and methods, which could have been crucial for safe utilization of forming hardware. A number of guidelines have been recommended for future research work. Appropriate guidelines have also been suggested regarding the relationship between process parameters and forming forces developed during the process in order to ensure the applicability of the ISF process on the industrial scale.

Section: Forming Machinery and Forming Forcementioning

confidence: 99%

Section: Forming Machinery and Forming Forcementioning

confidence: 99%

Forming force in incremental sheet forming: a comparative analysis of the state of the art

Gulati

J Braz. Soc. Mech. Sci. Eng.

et al. 2019

“…However, the major disadvantage is the less precision of the tool position; especially under high loads condition that limit robot arm capabilities in ISF operations. Belchior et al [13] and I.…”

Section: Introductionmentioning

confidence: 95%

“…On a NC milling machine, the execution of such finishing pass in a relatively short production time requires the use of the 4-axis mode allowing the rotation of workpieces about the Z-axis (tool axis). 13 (a) (b) (c) Fig 14. (a) Dome with double pass SPIF-T using 0.2 mm increment penetration, (b) and (c) dome after a finishing pass…”

Section: Effect Of the Penetration Incrementmentioning

confidence: 99%

SPIF process of axisymmetric parts made of AA1060-H14 aluminum alloy tested on 2 axis-NC lathe machine

Bs¹,

Bouhamed²,

Wali³

et al. 2020

Preprint

This paper deals with an experimental and numerical study focused on the SPIF process of a dome part manufactured by means of a 2-axis NC lathe machine. The main objective is to enhance the understanding of a set of parameters in connection with ISF operations applied to this type of machine unusually used in incremental forming processes, despite the high degree of development of NC lathe machines. Nowadays 4 and 5 axis lathe centers are widely used in industrial applications. This makes NC lathe machines useful in SPIF process especially in the case of axisymmetric parts. The present results, covering thinning, appearance of cracks, surface quality and FLD diagram; prove the efficiency of NC turning machines to perform SPIF application of parts commonly manufactured by a 3-axis NC milling machine.

“…The first one is an adaptive blank holder that acts in the vicinity of the forming tool and reduces unwanted secondary deformation that would lead to deviations from the target geometry. Belchior et al (2014) applied Process/Machine coupling approach to Robotized Incremental Sheet Forming (RISF) for Finite Element Analysis (FEA) of the process with an elastic modeling of the robot structure to improve the geometrical accuracy of the formed part. Lu et al (2013) presented a new feature-based tool path generation algorithm for incremental sheet forming process in which tool paths are generated according to the specified critical edges to improve geometric accuracy.…”

mentioning

confidence: 99%

Analysis of Pressure Assisted Incremental Sheet Forming Process through Simulation

Kumar¹,

Tjprc²

2018

IJMPERD

Incremental sheet forming (ISF) process is a flexible manufacturing process to produce complex 3D products at reasonable manufacturing cost. In addition to a single point, incremental sheet forming pressure has been applied to the back side of sheet surface in order to provide support to the sheet surface and improve process efficiency. In the current work, a comparative analysis of ISF & pressure assisted ISF process through CAE simulation have been done to predict the forming forces, energy requirements, effective stresses, etc. The forming forces in ISF as well as pressure-assisted ISF is very low when as compared to forming forces in traditional forming processes. The pressure-induced ductility hasresulted in the reduction of forming forces with pressure assisted ISF. The energy required in pressure assisted ISF is slightly higher than the ISF process. An increment in effective stresses is observed in pressure assisted ISF, which is a due application of force on both sides of the sheet. However, these stresses are local and very small when as compared to traditional forming processes.