Ductile damage and deformation mechanics in multistage single point incremental forming

Mirnia, Mohammad Javad; Vahdani, Mostafa; Shamsari, Mohsen

doi:10.1016/j.ijmecsci.2017.12.051

Cited by 47 publications

(14 citation statements)

References 36 publications

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“…This was also observed in the developed FE models of SPIF and DISF processes to form a hyperbolic cone. The same observation was reported by Mirnia et al (2018) in the FE simulation of SPIF process and by Smith et al (2013) in the FE simulation of SPIF and ADSIF. The localised material deformation in the TCBC test confirmed that the newly developed TCBC test could be a reasonable representation of the DSIF process.…”

Section: Discussionsupporting

confidence: 83%

Investigating formability enhancement in double side incremental forming by developing a new test method of tension under cyclic bending and compression

Dai

Long

2020

Journal of Materials Processing Technology

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Section: Discussionsupporting

confidence: 83%

Investigating formability enhancement in double side incremental forming by developing a new test method of tension under cyclic bending and compression

Dai

Long

2020

Journal of Materials Processing Technology

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“…However, the roughening in the external Al layer is more obvious than that in the external SUS layer, especially with a small tool diameter. In fact, the amount of free surface roughening is affected by the amount of plastic deformation and highly depends on the size of the grains [30]. In addition to the orange peel, clear micro crack and voids are observed on the external Al layer using the large tool diameter and step size.…”

Section: Microstructure Analysis Of the Bimetal Surfacesmentioning

confidence: 99%

Experimental Investigation and Optimal Prediction of Maximum Forming Angle and Surface Roughness of an Al/SUS Bimetal Sheet in an Incremental Forming Process Using Machine Learning

et al. 2019

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Bimetal sheets have superior properties as they combine different materials with different characteristics. Producing bimetal parts using a single-point incremental forming process (SPIF) has increased recently with the development of industrial requirements. Such types of sheets have multiple functions that are not applicable in the case of monolithic sheets. In this study, the correlation between the operating variables, the maximum forming angle, and the surface roughness is established based on the ensemble learning using gradient boosting regression tree (GBRT). In order to obtain the dataset for the machine learning, a series of experiments with continuous variable angle pyramid shape were carried out based on D-Optimal design. This design is created based on numerical variables (i.e., tool diameter, step size, and feed rate) and categorical variable (i.e., layer arrangement). The grid search cross-validation (CV) method was used to determine the optimum GBRT parameters prior to model training. After the parameter tuning and model selection, the model with a better generalization performance is obtained. The reliability of the predictive models is confirmed by the testing samples. Furthermore, the microstructure of the aluminum/stainless steel (Al/SUS) bimetal sheet is analyzed under different levels of operating parameters and layer arrangements. The microstructure results reveal that severe cracks are attained in the case of a small tool diameter while a clear refinement is observed when a high tool diameter value with small step down is used for both Al and SUS layers. different materials that have different characteristics, this strengthens the conductivity, corrosion resistance, and the yield strength of the combined sheet. The application of such processes to produce the desired composite parts combines the characteristics of both the forming process and the parent materials to enhance the quality and the formability of the low formable materials and reduce the cost and the weight of manufactured parts.The SPIF of composite sheets has generated considerable recent research interest. In the study of Al-Ghamdi and Hussain [1], the formability improvement of a Cu/steel bimetal sheet during SPIF was better than that in the stamping process due to the limitation of the delamination in the former process. In their further work [2], the relation between the maximum forming angle and the process parameters of the tri-layer Cu/steel/Cu was studied experimentally. The results of the study revealed that a complex relation was observed between the operating parameters of the tri-layer sheet. Gheysarian and Honarpisheh [3] investigated the effect of the layer arrangement, tool path, and tool diameter on formability (i.e., fracture depth) and surface quality of Al/Cu bimetal sheets. The results showed the improvement in the formability corresponding to a large tool diameter, spiral tool path, and copper layer as a contacted sheet. Later, Honarpisheh et al. [4] focused on the improvement of the maximum forming angl...

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“…In order to improve the wall angle more than what is attainable in single stage, incremental forming in multistages was attempted by few researchers. Mohammad Javad Mirnia et al [20] explained that, in 1mm thick aluminium alloy sheet, the formation of truncated cone with wall angle of 60 o for a height of approximately 15 mm was made without any fracture in two stage forming. Li Jun-chao et al [21] worked on DC06 Steel with 0.8mm thick using three stage forming at a wall angle of 30 o .…”

Section: Introductionmentioning

confidence: 99%

Investigation on component wall angle in single stage incremental forming of austenitic stainless steel AISI 304 sheet

Kumar¹,

Ethiraj²,

Sivabalan³

et al. 2020

FME Transactions

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The aim of this research work is to study the effect of process parameters in achieving the maximum possible wall angle of the component in single stage incremental forming. Austenitic stainless steel AISI 304 is used as a sheet material. The constant tool rotational speed of 250 rpm, tool feed of 1000 mm/min and incremental depth of 0.5 mm were used as process parameters and the wall angle was varied from 60 o .Grid marking technique is used for strain measurements. From the results, it is observed that the maximum height of 45 mm was formed successfully at wall angles 60 o , 61 o , 63 o and 64 o without any defects within the experimented process parameters. Further increase in either the wall angle or the process parameters produced fractured component at a height of around 22 mm itself.

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Ductile damage and deformation mechanics in multistage single point incremental forming

Cited by 47 publications

References 36 publications

Investigating formability enhancement in double side incremental forming by developing a new test method of tension under cyclic bending and compression

Investigating formability enhancement in double side incremental forming by developing a new test method of tension under cyclic bending and compression

Experimental Investigation and Optimal Prediction of Maximum Forming Angle and Surface Roughness of an Al/SUS Bimetal Sheet in an Incremental Forming Process Using Machine Learning

Investigation on component wall angle in single stage incremental forming of austenitic stainless steel AISI 304 sheet

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