Enhancing time efficiency on single point incremental forming processes

Abstract

Single Point Incremental Forming (SPIF) is a promising manufacturing technology concerning the production of customized products, low batches or prototyping of ready-to-use parts, given its easy implementation and absence of dedicated tooling. The range of application is wide, covering many materials and virtually unlimited geometries. Indeed, nowadays' process downsides are more related to high forming times and dimensional inaccuracy. There are many processing parameters that can be optimized to circumvent such problems. In this work, focus is given on the effect of increasing tool feed rate. To this end, a dedicated SPIF machine is employed. After forming steel and aluminum sheets, parameters like forming force, maximum wall angle and formability are assessed for a range of velocities from 1500 to 12,000 mm/min. Parameters like step down or tool diameters are kept constant for a clear comparison. It will be shown how the process can be fastened up without seriously compromising its feasibility.

Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation

“…To circumvent the delay in forming time, high-speed forming was performed by increasing the tool feed rate in the range of 1500-12,000 mm/min. By this, delay in forming process was eliminated without compromising the feasibility and accuracy [2]. To make the process industrially appropriate, improvements in process characteristics such as forming load, forming limits, geometrical accuracy and surface quality of the formed parts are essential.…”

Investigation of tool wear in single point incremental sheet forming

“…Analyzing the studies referenced, 23,27,35,51 it is noted that the current research complements these previous studies because it uses intermediate technological conditions of Ap, feed rate (f) and v, not covered by the cited references.…”

“…As there are three unknowns with a variation in three levels, the tests were carried out by opting to execute all possible combinations between these values, resulting in 27 tests (no replication), according to Table 2, with technological conditions Ap, feed rate (f) and v, not covered in the literature. 23,27,35,51 To mark the end of each test, the maximum tool wear of 0.10 mm or the conformation of a batch of 10 pieces was used as a parameter, whichever occurs first. This 0.10-mm wear parameter was used because it is the lowest value in the literature for tool wear, based on a piece of simple and symmetrical geometry, as shown in Figure 7.…”

“…As there are three unknowns with a variation in three levels, the tests were carried out by opting to execute all possible combinations between these values, resulting in 27 tests (no replication), according to Table 2, with technological conditions Ap , feed rate ( f ) and ω , not covered in the literature. 23,27,35,51…”

“…Pereira Bastos et al 51 shows that surface roughness also increases with an increase in the feed rate ( f = 1500, 2500, 3500 and 12.000 mm/min) and used tool not rotating ( ω = 0 r/min).…”