Design and Fabrication Methodologies for Repurposing End of Life Metal via Robotic Incremental Sheet Metal Forming

Nicholas, Paul; Chiujdea, Ruxandra Stefania; Sonne, Konrad; Scaffidi, Antonio

doi:10.52842/conf.ecaade.2021.2.171

Cited by 4 publications

(2 citation statements)

References 4 publications

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“…Una vez terminado el proceso descrito, métodos de compensación a través de escaneado 3D y simulación de elementos finito (FEA, por su sigla en inglés) fueron ejecutados para minimizar la variación geométrica. Por otra parte, Nicholas et al (2021) propusieron una metodología para reutilizar objetos en desuso a través del proceso de conformado incremental robótico y así, evitar costos energéticos asociados a procedimientos tradicionales de reciclaje. Mediante un flujo de trabajo que incluye escáner 3D, procesamiento de datos y configuraciones de fabricación, los autores no solo aumentaron la vida útil de un producto desechado, sino que modificaron su uso original.…”

Section: Introductionunclassified

Robotic Incremental Sheet Metal Forming: Waste Management Through Digital Fabrication

Véliz,

Benavides,

Tala

et al. 2024

Blucher Design Proceedings

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Section: Introductionunclassified

Robotic Incremental Sheet Metal Forming: Waste Management Through Digital Fabrication

Véliz,

Benavides,

Tala

et al. 2024

Blucher Design Proceedings

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“…Single-point incremental forming (SPIF) has gained prominence as a cost-effective and rapid method for manufacturing sheet metal parts, complementing traditional machining techniques, and seamlessly integrating with computer numerical control (CNC) machines. Its versatility has led to its adoption across a multitude of industries, including aerospace [1,2], automotive [3,4], molds [5], medical devices [6][7][8], architecture [9,10], and beyond. Nevertheless, challenges persist in SPIF, particularly regarding defects in wall thickness uniformity, geometric accuracy, and other process limitations, which impede its broader industrial applications.…”

Section: Introductionmentioning

confidence: 99%

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

Hoang,

Luyen,

Nguyen

2023

Materials

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Single-point incremental forming (SPIF) has emerged as a cost-effective and rapid manufacturing method, especially suitable for small-batch production due to its minimal reliance on molds, swift production, and affordability. Nonetheless, SPIF’s effectiveness is closely tied to the specific characteristics of the employed sheet materials and the intricacies of the desired shapes. Immediate experimentation with SPIF often leads to numerous product defects. Therefore, the pre-emptive use of numerical simulations to predict these defects is of paramount importance. In this study, we focus on the critical role of the forming limit curve (FLC) in SPIF simulations, specifically in anticipating product fractures. To facilitate this, we first construct the forming limit curve for Al1050 sheet material, leveraging the modified maximum force criterion (MMFC). This criterion, well-established in the field, derives FLCs based on the theory of hardening laws in sheet metal yield curves. In conjunction with the MMFC, we introduce a graphical approach that simplifies the prediction of forming limit curves at fracture (FLCF). Within the context of the SPIF method, FLCF is established through both uniaxial tensile deformation (U.T) and simultaneous uniform tensile deformation in bi-axial tensile (B.T). Subsequently, the FLCF predictions are applied in simulations and experiments focused on forming truncated cone parts. Notably, a substantial deviation in fracture height, amounting to 15.97%, is observed between simulated and experimental samples. To enhance FLCF prediction accuracy in SPIF, we propose a novel method based on simulations of truncated cone parts with variable tool radii. A FLCF is then constructed by determining major/minor strains in simulated samples. To ascertain the validity of this enhanced FLCF model, our study includes simulations and tests of truncated cone samples with varying wall angles, revealing a substantial alignment in fracture height between corresponding samples. This research contributes to the advancement of SPIF by enhancing our ability to predict and mitigate product defects, ultimately expanding the applicability of SPIF in diverse industrial contexts.

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Reshaping of thin steel parts by cold and warm flattening

et al. 2023

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Approximately half of global steel production is dedicated for manufacturing sheets. Due to global warming, geopolitical instabilities and rising raw material costs, recycling sheet metal is increasingly important. Conventional recycling has inefficiencies, therefore improving material efficiency and adopting circular economy strategies is necessary to halve CO2 emissions by 2050. This paper presents a review of sheet metal reuse techniques and introduces an innovative remanufacturing framework of curved steel sheet, with a special focus on the automotive sector and car-body panels. To support the framework presented, an experimental procedure on small-scale samples was carried out. The material tested was DC 0.4 steel parts (0.8 mm thick) characterized by different curvature radii. The material was reshaped and flattened under different conditions to understand the effect of the process variables onto the final quality of the remanufactured parts. The experiments showed that even parts with small curvatures can be flattened and reshaped with success. Lastly, to support the general remanufacturing framework presented, some flattening simulations of a large car-body are presented, revealing the importance of implementing a dwelling stage in the process and the advantage of performing such process with heated tools.

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Design and Fabrication Methodologies for Repurposing End of Life Metal via Robotic Incremental Sheet Metal Forming

Cited by 4 publications

References 4 publications

Robotic Incremental Sheet Metal Forming: Waste Management Through Digital Fabrication

Robotic Incremental Sheet Metal Forming: Waste Management Through Digital Fabrication

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

Reshaping of thin steel parts by cold and warm flattening

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