Comparison between aluminum alloys behavior in incremental sheet metal forming process of frustum pyramid shaped parts

Abstract

Single point incremental forming is a new emerging technology, used mainly for prototype development or small series production, with good prospects in industrial implementation. However, the parts manufactured through this process often presents low accuracy, thus the industrial implementation is yet limited. Incremental forming process can be done with the help of different technological equipment, such as industrial robots and numerically controlled machines. Since the process is still in development phase, it is a good practice to use finite element analysis software packages in order to reduce time and costs to produce accurate parts. The aim of this paper is to investigate the behavior of different aluminum alloys deformed through SPIF regarding forming forces, thickness distribution and springback effect. Based on numerical simulations performed, the material which produces the most accurate parts for the frustum cone can be chosen for further experimental research.

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

“…They found that forming sheets incrementally with ultrasonic assistance can reduce the springback effect. Rusu et al [146] studied the behaviour of the following various aluminium alloys: AA 2007, EN AW 5754 and EN AW 6060 that were formed using SPIF, examining forming forces, thickness distribution and springback. The largest springback effect was seen in the AA 2007 alloy, which was accompanied by the lowest accuracy.…”

Incremental forming using KUKA KR210-2 industrial robot - research regarding design rules and process modelling

“…With the use of the same equipment, due to the great flexibility of the process, there are many manufacturing possibilities of the different shapes and sizes of parts. However, the complexity of the geometric shapes that can be formed depends on many process parameters [10][11][12], such sheet thickness, forming angle, tool size, step size, punch toolpath or the available power of the technical equipment.…”

Shape Accuracy in Single Point Incremental Forming of Conical Frustums from Titanium CP2 Sheets

“…The springback was found to increase with increasing tool diameter. Rusu et al (2021) studied the behaviour of different EN AW-2007, EN AW-5754 and EN AW-6060 aluminium alloy sheets deformed through SPIF regarding springback effect. Frustum pyramids made of EN AW-2007 alloy presented the highest springback.…”