Experimental Analysis of Single Point Incremental Forming of Truncated Cones in DC04 Steel Sheet

Krasowski, Bogdan; Kubit, Andrzej; Trzepieciński, Tomasz; Slota, Ján

doi:10.2478/adms-2020-0018

Cited by 6 publications

(5 citation statements)

References 22 publications

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“…Using the basic parameters, first the maximum depth of the stiffening rib was determined by an experimental method. Based on the previous experiences of the authors [35,36], an attempt was made to form an embossing with a depth of D = 7 mm. In the forming process, cracking of the outer cover was observed with the tool recess equal to 6.65 mm.…”

Section: Resultsmentioning

confidence: 99%

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Analysis of the Possibility of Forming Stiffening Ribs in Litecor Metal-Plastic Composite Using the Single Point Incremental Forming Method

Trzepieciński

Korzeniowski

Bobusia

et al. 2022

KEM

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Efforts to reduce COx are extremely important, which forces the use of materials and technologies that reduce the weight of means of transport in order to reduce energy consumption. Currently, aluminum alloys and FRP composites are still too expensive for mass industry applications. Presented in this study, Litecor is a three-layer composite that combines the high strength of steel with the low density of plastic. Thanks to the use of external steel covers 0.3 mm thick and a light core 0.7 mm thick, high stiffness was achieved while maintaining a relatively low weight. The weight reduction in comparison with steel blanks with the same stiffness is up to 40%. Litecor is mainly developed by ThyssenKrupp, it is a promising construction material, but it requires development the technology of forming and joining. In this study, the possibility of forming the Litecor layered composite was investigated using the single-point incremental sheet forming (SPIF) method. As part of the research, the stiffening ribs were shaped, the maximum depth of the embossing was determined. The degree of thinning in selected cross-sections of the embossing was determined. The influence of the rotational speed of the tool and the feed rate on the properties of the shaped surface was also analyzed. Incorrectly selected shaping parameters have been shown to damage the zinc coating on the inner surface of the embossing.

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Section: Resultsmentioning

confidence: 99%

“…A simple tool with a longitudinal groove with the target crease width was used as a forming matrix. The shaping was performed first with the use of basic parameters selected on the basis of the authors' previous experiences [35,36]. The forming process was carried out using a continuous spiral-shaped toolpath.…”

Section: Methodsmentioning

confidence: 99%

Analysis of the Possibility of Forming Stiffening Ribs in Litecor Metal-Plastic Composite Using the Single Point Incremental Forming Method

Trzepieciński

Korzeniowski

Bobusia

et al. 2022

KEM

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“…The depth of embossing (D) was determined to be 5 mm through experimentation. The research utilized a longitudinal groove SPIF tool to create the necessary forming matrix, with the initial parameters informed by previous studies [ 28 , 29 ].…”

Section: Methodsmentioning

confidence: 99%

Analysis of Surface Texture and Roughness in Composites Stiffening Ribs Formed by SPIF Process

et al. 2023

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Studying roughness parameters and the topography of stiffening ribs in composite sandwich structures is important for understanding these materials’ surface quality and mechanical properties. The roughness parameters describe the micro-geometry of the surface, including the average height deviation, roughness depth, and waviness. The topography of the surface refers to the spatial arrangement and distribution of features such as bumps, ridges, and valleys. The study investigated the roughness parameters under three scenarios based on two SPIF process parameters: tool rotational speed(N) and feed rate (f). The vertical step was held constant at 0.4 mm across all scenarios. In scenario A, the process parameters were set at f = 300 mm/min and n = 300 rpm; in scenario B, f = 1500 mm/min and n = 3000 rpm; and in scenario C, f = 1500 mm/min and n = 300 rpm. The experimental research topography analyses revealed that the surface roughness of the stiffened ribs was highly dependent on the SPIF process parameters. The highest feed rate and tool rotational speed produced the smoothest surface texture with the lowest maximum height (Sz) value. In contrast, the lowest feed rate and tool rotational speed resulted in a rougher surface texture with a higher maximum height (Sz) value. Furthermore, the contour plots generated from the topography analyses provided a good visual representation of the surface texture and roughness, allowing for a more comprehensive analysis of the SPIF process parameters. This study emphasizes optimizing the SPIF process parameters to achieve the desired surface quality and texture of stiffened ribs formed in Litecor® panel sheets.

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“…Additionally, higher spindle speeds correlated with increased surface roughness. Krasowski et al [14] investigated the impact of forming parameters and tool strategy on the surface roughness in the single-point incremental forming process, specifically focusing on shaping thin-walled panels with longitudinal stiffening. The study utilized aluminum-clad material (Al 2024-T3) with a thickness of 0.4 mm, and under investigation parameters included spindle speed, feed rate, and tool path strategy.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Single-Point Incremental Forming Process Parameters on the Surface Roughness of Aluminum Alloy Al 2024-O Draw Pieces

Habeeb,

Jweeg,

Khleif

2023

Adv. Sci. Technol. Res. J.

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The incremental sheet metal forming process is a highly adaptable manufacturing process for producing threedimensional products without the need for specialized tool typically required in traditional forming processes. This innovative process finds extensive applications in various industries, including aerospace, automobile, and other industrial applications. This study explores the application of the single-point incremental forming (SPIF) process to manufacture truncated pyramids while investigating the impact of specific process parameters on surface roughness. In this study, three parameters wall angle, sheet thickness, and step depth were examined, each at three different levels. A full factorial design (L27) was used to design the experimental work and statistical analysis utilizing Analysis of Variance (ANOVA) was utilized to analyze the collected data and predict the impact of single-point incremental forming process parameters on surface roughness. The tool geometry was a hemispherical end tool with a diameter of (8 mm) and the sheet material was aluminum alloy (Al 2024-O). The computer numerical control (CNC) milling machine was used to move the tool. The optimal average roughness (Ra) value was achieved with a wall angle of 60°, a sheet thickness of 2 mm, and a step depth of 0.2 mm.

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Experimental Analysis of Single Point Incremental Forming of Truncated Cones in DC04 Steel Sheet

Cited by 6 publications

References 22 publications

Analysis of the Possibility of Forming Stiffening Ribs in Litecor Metal-Plastic Composite Using the Single Point Incremental Forming Method

Analysis of the Possibility of Forming Stiffening Ribs in Litecor Metal-Plastic Composite Using the Single Point Incremental Forming Method

Analysis of Surface Texture and Roughness in Composites Stiffening Ribs Formed by SPIF Process

Effect of the Single-Point Incremental Forming Process Parameters on the Surface Roughness of Aluminum Alloy Al 2024-O Draw Pieces

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