Incremental sheet metal forming on the example of car exterior skin parts

Scheffler, Sören; Pierer, Alexander; Scholz, Peter; Melzer, Sebastian; Weise, Dieter; Rambousek, Zdeněk

doi:10.1016/j.promfg.2019.02.112

Cited by 24 publications

(9 citation statements)

References 5 publications

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“…In one of the case studies in automobile sector, Omar 20 reported that 35% of blank sheet material is scrapped without being used in making parts while employing conventional forming methods. Scheffler et al 122 reported that most of outer skin parts of the demonstrator vintage car, the required sheet material and tooling cost using ISF method is less than deep drawing and hydroforming. Researchers 86 studied part-to-blank ratio for ISF-cone and pyramid geometries, and found that trimming yield was up to 15% in stamping, and up to 65% on average for car parts 20 and 68% for car doors.…”

Section: Sustainability Performance Of Incremental Sheet Formingmentioning

confidence: 99%

Energy consumption, carbon emissions, product cost, and process time in incremental sheet forming process: A holistic review from sustainability perspective

Riaz

Hussain

Iqbal

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Due to continuous worsening of the environment and depletion of natural resources, concept of sustainability in manufacturing sector is gaining an increasing attention. New processes and strategies characterized by efficient use of energy and materials, low processing time and zero or nearly zero green-house emissions are being explored. Incremental sheet forming (ISF) is a comparatively new sheet forming process with high economic payoff for small production runs and customized orders. The current study presents a comprehensive review on the sustainability aspects of the process. The process performance in terms of power demand, energy consumption, cost, CO2 emissions, processing time, and material wastage/usage is analyzed on the basis of published literature, and important conclusions and recommendations are drawn to utilize the process for cleaner, economical and time efficient production. The review establishes that ISF is more sustainable process than conventional forming methods for small production runs. Further, its sustainability performance can be further enhanced by choosing optimum process conditions especially lower spindle rotation, larger feed rate and step size. Shorter tool paths and advent of energy efficient machines is likely to further elevate the process performance. The review also identifies future work and presents fundamental guidelines and recommendations for establishing the sustainable ISF process.

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Section: Sustainability Performance Of Incremental Sheet Formingmentioning

confidence: 99%

Energy consumption, carbon emissions, product cost, and process time in incremental sheet forming process: A holistic review from sustainability perspective

Riaz

Hussain

Iqbal

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Due to the advantages of high material utilization and stable product function, sheet metal has been widely used in important manufacturing fields, such as automobiles and home appliances. [1][2][3][4] Hence, improving the automation and quality of sheet metal production has always been a hot issue in the industry. [5][6][7] Based on the characteristics of metal plastic deformation, a bending workpiece with a specified angle is obtained through the extrusion of the upper and lower dies.…”

Section: Introductionmentioning

confidence: 99%

Research on the angle measurement system of bending workpieces based on multi-line structured light

He,

Xie,

Liu

et al. 2023

Opt. Eng.

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.Nowadays, bending workpiece angle measurement methods require touching the surface, which makes them prone to scratching the workpieces and inefficient. To solve the above problems, we propose a non-contact angle measurement system based on multi-line structured light. First, a bilinear laser is projected onto the surface of the workpiece and the machine tool lower die. However, reflections on the smooth workpiece will greatly destroy measurement accuracy. In this work, a UNet-based multi-exposure image fusion strategy is proposed to clip the reflection and increase the workpiece feature. Then, the Steger algorithm is used to achieve high-precision localization of the laser centerline. Finally, the angle of the workpiece is calculated indirectly according to fitting the laser centerline plane. The experimental results demonstrate that the measurement time of each workpiece is less than 100 ms and the measurement accuracy is ±0.3 deg in extreme installation locations and shadow. The proposed system can be extended to real industrial scenarios because of its high efficiency, accuracy, and robustness.

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“…In Single Point Incremental Forming (SPIF), the final shape of the piece being manufactured is defined by the hemispheric-tipped tool's trajectory, which progressively deforms a plane sheet [1]. This is a flexible process that does not require dedicated tools [2] and can be used in the fabrication of individual parts or small lots of parts [3,4].…”

Section: Introductionmentioning

confidence: 99%

Predicting maximum force in SPIF for different materials

et al. 2022

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Knowing the importance of predicting acting forces during the formation process, our research has conducted 27 Single Point Incremental Forming (SPIF) experiments in hyperboloid format, followed by Finite Element Method (FEM) simulations and regression equations were determined to estimate the maximum axial force in the process. ANOVA analysis of variance was used to determine the significance of material parameters in the maximum axial force response. A multiple linear regression model was constructed to estimate the maximum axial force in the SPIF process. After the experiments, we were able to identify that the maximum axial force increases according to an increase in tool radius, sheet initial thickness, and strength coefficient values, as well as according to the decrease in the strain-hardening exponent. The FEM simulations are in agreement with the experimental values found, and the linear regression model has proven to be efficient to describe results, with R2 of 98.85% and a maximum percentage error of 11.5%.

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Incremental sheet metal forming on the example of car exterior skin parts

Cited by 24 publications

References 5 publications

Energy consumption, carbon emissions, product cost, and process time in incremental sheet forming process: A holistic review from sustainability perspective

Energy consumption, carbon emissions, product cost, and process time in incremental sheet forming process: A holistic review from sustainability perspective

Research on the angle measurement system of bending workpieces based on multi-line structured light

Predicting maximum force in SPIF for different materials

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