An Investigation of the Impact of Forming Process Parameters in Single Point Incremental Forming Using Experimental and Numerical Verification

Abstract

Incremental sheet forming (ISF) is an innovative cold forming operation and has enticed great interests owing to its flexibility and capability to manufacture various complex 3D shapes with low costs and minimum requirements. Single point incremental forming (SPIF) is the most popular type of ISF process and has high quality and less occurrence of defects for the formed products if the operating parameters are achieved and evaluated with high precision. In this study, the impact of tool diameter and forming angle on the forming force, thickness distribution, thinning ratio, effective plastic strain, forming depth and fracture behaviour was explored. AA1050 aluminium alloy and DC04 carbon steel were employed to produce a truncated cone in accordance with the SPIF process. A 3D finite element model was required to achieve a well-established investigation. The SPIF of a truncated cone numerical model was adopted to build a model with the same conditions as of the experimental work with aid of ANSYS software version 18 through using the workbench LS-DYNA model. The sheet metal modelling was carried out in accordance the Cowper Symonds power law hardening by taking the behaviour of the material as elastic–plastic, and the anisotropic properties were assumed to simulate the plasticity behaviour for two sheet metals. Results indicate that the DC04 carbon steel has a higher forming force, minimum thickness and lower thinning ratio compared with AA1050 aluminium alloy under the same operating conditions.

Improve Single Point Incremental Forming Process Performance Using Primary Stretching Forming Process

“…Figure 9 present the thickness distribution for both SPIF processed part and Stretching primary forming at 10, 20, 30, and 40 mm forming depth with SPIF process, the minimum thickness was obtained is 0.40 mm in the case of using pure SPIF, however, the plate thickness is reached 0.43, 0.44, 0.46, and 0.51 mm for applying initial forming depth of 10, 20, 30, and 40 mm, respectively. The large reduction in thickness along the wall of SPIF is probably due to the increase in plastic deformation that occurred in the sheet at small forming zone during using the SPIF method [16], the high reduction in wall thickness is not desirables in the engineering application [17]. In the other word, the primary stretching forming process has a significant effect on the distribution of thickness in the SPIF process compared to the effects of other parameters including step size, tool diameter, and feed rate [18].…”

Mechanical Properties of 3D-Printed PETG Samples: The Effect of Varying Infill Patterns

“…Most importantly, the properties of additively manufactured components using 3D printing technique are affected by the filling factor, print and raster direction, and layer-to-layer thickness [30]. There is a great deal of studies [31][32][33][34][35][36][37][38][39][40][41][42][43][44][45][46][47][48][49] analyzing the effect of various variables on mechanical characteristics, especially tensile characteristics. Camposeco-Negrete [50] analysed the impact of layer print size, infill shape, raster direction of 3D-printed parts using Taguchi and ANOVA methods.…”

Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of Al1050 Sheet Material

“…Nevertheless, challenges persist in SPIF, particularly regarding defects in wall thickness uniformity, geometric accuracy, and other process limitations, which impede its broader industrial applications. To address these limitations and enhance SPIF's predictability, a considerable body of research has been dedicated to numerical simulations of the forming process [11][12][13][14][15][16][17].…”