High-Speed Incremental Forming Process: A Trade-Off Between Formability and Time Efficiency

Khalatbari, Hosein; Iqbal, Asif; Shi, Xianqing; Lin, Gao; Hussain, G.; Hashemipour, Majid

doi:10.1080/10426914.2015.1037892

Cited by 34 publications

(14 citation statements)

References 24 publications

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“…The CAD model wall angle starts from θ i = 30°at the sample opening, which increases to 75°at the bottom of the cone. As suggested by Khalatbari et al [13], the wall angle was designed to increase by a constant ratio in accordance with the component depth (h i ), and is given by Equation 1.…”

Section: Experimental Setup and Designmentioning

confidence: 99%

Effects of the relative tool rotation direction on formability during the incremental forming of titanium sheets

Uheida

Oosthuizen

Dimitrov

et al. 2018

Int J Adv Manuf Technol

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The effects of tool rotation direction during single point incremental forming of pure titanium were experimentally studied. Axisymmetric components with a varying wall angle were formed using a round-tipped tool of 10 mm diameter and following a 3D spiral tool path. Test runs were executed by changing one factor at a time. Spindle rotation was tested in both the climb and the conventional directions. Tool step depth between runs was increased by a fixed interval over the range of 0.35 mm up to the plate thickness of 0.8 mm. The experimental results obtained by a comparison between the two forming strategies and their impact on the characteristics of formability are discussed in this paper. The achieved level of the forming angle (75°), and the reduction in geometric deviations from the conventional strategy, presents interesting findings. Considerable variations in the trends of forces and temperature between the two forming strategies are presented and discussed.

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Section: Experimental Setup and Designmentioning

confidence: 99%

Effects of the relative tool rotation direction on formability during the incremental forming of titanium sheets

Uheida

Oosthuizen

Dimitrov

et al. 2018

Int J Adv Manuf Technol

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“…1. This was made to minimize the effect on material formability that might result from the rate at which the wall angle changes as the forming depth increases [19].…”

Section: Methodsmentioning

confidence: 99%

Formability of titanium alloy sheets by friction stir incremental forming

Grün

Uheida

Lachmann

et al. 2018

Int J Adv Manuf Technol

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This paper investigates the behavior of titanium formability when forming under localized friction heating, caused by high tool rotation. In accordance with planned experiments, different process conditions at various tool rotations, feed rates, and step-down sizes were investigated. The experiments were carried out on 1 mm thick Ti6Al4V alloy sheets, using an 11 mm diameter, ballended tooltip. The rotational speeds were designed to create sufficient thermal effect, while maintaining high lubricity at the forming interface. Moderate tool rotational speed (2000 rpm) tends to improve formability, reduce the forces, and lower the rate of tool wear. The experimental procedures are presented, and an extensive discussion of the results is reported.

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“…Many optimisation techniques have been employed to optimise process parameters till the date. Artificial neural network (ANN), support vector regression (SVR) and genetic algorithm (GA) were used to optimise parameters in ISF [11]. ANN and SVR performed better than GA and predicted results were in very good agreement with the experimental value.…”

Section: Introductionmentioning

confidence: 99%

Influence of process parameters on surface roughness and forming time of Al-1100 sheet in incremental sheet metal forming

Mohanty

Regalla

Rao

2019

JMES

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Product quality and production time are critical constraints in sheet metal forming. These are normally measured in terms of surface roughness and forming time, respectively. Incremental sheet metal forming is considered as most suitable for small batch production specifically because it is a die-less manufacturing process and needs only a simple generic fixture. The surface roughness and forming time depend on several process parameters, among which the wall angle, step depth, feed rate, sheet thickness, and spindle speed have a greater impact on forming time and surface roughness. In the present work, the effect of step depth, feed rate and wall angle on the surface roughness and forming time have been investigated for constant 1.2 mm thick Al-1100 sheet and at a constant spindle speed of 1300 rpm. Since the variable effects of these parameters necessitate multi-objective optimization, the Taguchi L9 orthogonal array has been used to plan the experiments and the significance of parameters and their interactions have been determined using analysis of variance (ANOVA) technique. The optimum response has been brought out using response surfaces. Finally, the findings of response surface method have been validated by conducting additional experiments at the intermediate values of the parameters and these results were found to be in agreement with the predictions of Taguchi method and response surface method.

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High-Speed Incremental Forming Process: A Trade-Off Between Formability and Time Efficiency

Cited by 34 publications

References 24 publications

Effects of the relative tool rotation direction on formability during the incremental forming of titanium sheets

Effects of the relative tool rotation direction on formability during the incremental forming of titanium sheets

Formability of titanium alloy sheets by friction stir incremental forming

Influence of process parameters on surface roughness and forming time of Al-1100 sheet in incremental sheet metal forming

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