Experimental and numerical investigation on incremental sheet forming with flexible die-support from metallic foam

Min, Junying; Kuhlenkötter, Bernd; Shu, Changle; Störkle, Denis Daniel; Thyssen, Lars

doi:10.1016/j.jmapro.2017.12.013

Cited by 27 publications

(8 citation statements)

References 22 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In addition, to have controlled plastic flow in SPIF, metallic foam blocks were also used as flexible die-support. This method proved to improve the accuracy of the formed part along with maintaining the flexibility of the process [14]. Parts formed by SPIF suffer from global springback due to Bauschinger effect of the sheet material.…”

Section: Introductionmentioning

confidence: 99%

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

Shrivastava

Kumar

Tandon

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

The work involves finite element analysis (FEA) and experimental investigation of formability and geometrical accuracy prevailing in single point incremental forming (SPIF) process. Preheating at different temperatures was performed in order to reform microstructures (grain size) and texture (spatial grain orientation distribution) of AA1050 sheet. Preheating led to removal and rearrangements of defects in the crystal structure in comparison with the distorted structures present in coldworked commercial aluminum sheets. Preheating at higher temperatures resulted in coarser grains with preferential texture and increased area fraction of homogenously oriented grains. Numerical simulation of SPIF process has been done to predict the effect of preheating on von Mises stresses, forming load, wall thickness distribution and geometrical accuracy of formed parts. For the purpose, Johnson-Cook models' parameters were evaluated by mechanical characterization of the samples with varying microstructural and texture arrangements resulted due to variations in preheating temperatures. FEA of the process revealed that preheating of the sheets resulted in reduced forming load, uniform wall thickness distribution and improved geometrical accuracy. The results were further validated by experiments and compared to the original samples with fine and randomly orientated grains.

show abstract

Section: Introductionmentioning

confidence: 99%

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

Shrivastava

Kumar

Tandon

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

show abstract

“…Due to aforementioned advantages, this process is widely adopted in industrial applications such as medical, automotive, aerospace, and civil sectors [1][2][3][4][5]. However, although this process has noticeable advantages, it also tends to have drawbacks [6][7][8][9][10], including the material formability [11] issues such as achieving proper height and wall angle, controlling thinning behavior, reducing forming force [12][13][14], and the pillow effect. Nevertheless, the significant demand still rises in this process to obtain an excellent surface finish on the incrementally formed parts.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Forming Parameters in Incremental Sheet Forming of AA3003-H18 Sheets Using Taguchi Method

Murugesan

Jung

et al. 2022

Materials

View full text Add to dashboard Cite

The surface finish is an important characteristic in the incremental sheet forming (ISF) process and is often influenced by numerous factors within the forming process. Therefore, this research was aimed at identifying the optimal forming parameters through the Taguchi method to produce high-quality formed products. The forming tool radius, spindle speed, vertical step increment, and feed rate were chosen as forming parameters in the experimental design, with surface roughness as the response variable. Taguchi L16 orthogonal array design and analysis of variance (ANOVA) test were used to identify the parameter’s optimal settings and examine the statistically significant parameters on the response, respectively. Results confirmed that a significant reduction in surface roughness occurred with a drop in vertical step size and an increase in feed rate. In detail, the vertical step size has the most significant influence on the surface roughness, followed by the feed rate and the forming tool radius. In conclusion, the optimum level settings were obtained: forming tool radius at level 3, spindle speed at level 1, vertical step size at level 1, and feed rate at level 4. Additionally, confirmation experiment results based on the optimal settings indicated a good agreement against the experimental observation. Further, the response surface methodology (RSM) was also exploited to devise a mathematical model for predicting the surface roughness. The results comparison confirmed that both techniques could effectively improvise the surface finish.

show abstract

“…Existing conventional metal forming methods are designed to produce only predefined shapes; in the case of design alteration, the entire experimental setup has to be redesigned in terms of manufacturing tools. This kind of preparation requires more production time, increasing the costs by manufacturing new parts such as dies, punches, and molds [ 3 ]. However, the incremental sheet forming process (ISF) does not require any external die to produce the desired components as the new parts can be manufactured using the predefined contour tool path.…”

Section: Introductionmentioning

confidence: 99%

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Murugesan

Jung

2021

Materials

View full text Add to dashboard Cite

The single-point incremental forming process (SPIF) is one of the emerging manufacturing methods because of its flexibility in producing the desired complex shapes with higher formability at low-cost compared to traditional sheet forming methods. In this research work, we experimentally investigate the forming process to determine the influence of process parameters and their contribution to enhancing the formability without causing a fracture by combining the design of experiments (DOE), grey relational analysis (GRA), and statistical analysis of variance (ANOVA). The surface morphology and the energy dispersive X-ray spectroscopy (EDS) method are used to perform elemental analysis and examine the formed parts during three forming stages. The DOE procedure, a central composite design with a face-centered option, is devised for AA3003-H18 Al alloy sheet for modeling the real-time experiments. The response surface methodology (RSM) approach is adopted to optimize the forming parameters and recognize the optimal test conditions. The statistically developed model is found to have agree with the test measurements. The prediction model’s capability in R2 is computed as 0.8931, indicating that the fitted regression model adequately aligns with the estimated grey relational grade (GRG) data. Other statistical parameters, such as root mean square error (RMSE) and average absolute relative error (AARE), are estimated as 0.0196 and 2.78%, respectively, proving the proposed regression model’s overall closeness to the measured data. In addition, the prediction error range is identified as −0.05 to 0.05, which is significantly lower and the residual data are distributed normally in the design space with variance and mean of 3.3748 and −0.1232, respectively. ANOVA is performed to understand the adequacy of the proposed model and the influence of the input factors on the response variable. The model parameters, including step size, feed rate, interaction effect of tool radius and step size, favorably influence the response variable. The model terms X2 (0.020 and 11.30), X3 (0.018 and 12.16), and X1X2 (0.026 and 9.72) are significant in terms of p-value and F-value, respectively. The microstructural inspection shows that the thinning behavior tends to be higher as forming depth advances to its maximum; the deformation is uniform and homogeneous under the predefined test conditions.

show abstract

Experimental and numerical investigation on incremental sheet forming with flexible die-support from metallic foam

Cited by 27 publications

References 22 publications

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

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

Optimization of Forming Parameters in Incremental Sheet Forming of AA3003-H18 Sheets Using Taguchi Method

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Contact Info

Product

Resources

About