Process window enhancement for single point incremental forming through multi-step toolpaths

Duflou, Joost R.; Verbert, Johan; Belkassem, Bachir; Gu, Jun; Sol, Hugo; Henrard, Christophe; Habraken, Anne Marie

doi:10.1016/j.cirp.2008.03.030

Cited by 181 publications

(89 citation statements)

References 10 publications

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“…Thus, it is straightforward to hypothesize that in order to increase the maximum wall angle, one could increase the initial thickness. However, this strategy has its practical limitations like the maximum machine load and thickness specifications of the material batch (Duflou et al, 2008).…”

Section: Bendingmentioning

confidence: 99%

Damage prediction in single point incremental forming using an extended Gurson model

Guzmán

Yuan

Duchêne

et al. 2018

International Journal of Solids and Structures

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Single point incremental forming (SPIF) has several advantages over traditional forming, such as the high formability attainable by the material. Different hypotheses have been proposed to explain this behavior, but there is still no straightforward relation between the particular stress and strain state induced by SPIF and the material degradation leading to localization and fracture. A systematic review of the state of the art about formability and damage in SPIF is presented and an extended Gurson-TvergaardNeedleman (GTN) model was applied to predict damage in SPIF through finite element (FE) simulations. The line test was used to validate the simulations by comparing force and shape predictions with experimental results. To analyze the failure prediction, several simulations of SPIF cones at different wall angles were performed. It is concluded that the GTN model underestimates the failure angle on SPIF due to wrong coalescence modeling. A physically-based Thomason coalescence criterion was then used leading to an improvement on the results by delaying the onset of coalescence.

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Section: Bendingmentioning

confidence: 99%

Damage prediction in single point incremental forming using an extended Gurson model

Guzmán

Yuan

Duchêne

et al. 2018

International Journal of Solids and Structures

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“…Concerning the current research related to multi-pass ISF process, Duflou et al [20] investigated the difference of material deformation between multi-pass and single pass ISF.…”

Section: Introductionmentioning

confidence: 99%

An efficient method for thickness prediction in multi-pass incremental sheet forming

Cao

Lü

et al. 2014

Int J Adv Manuf Technol

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“…The generation of intelligent toolpath strategies has been the key to improved part manufacture in all of these aspects. Process limits were enhanced using multi-step toolpaths as illustrated by Duflou et al [11]. The use of helical toolpaths as shown by Skjødt et al [12] and Cao et al [13] helps eliminate scarring caused by the tool stepping down in a contouring toolpath.…”

Section: Introductionmentioning

confidence: 99%

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Behera

Lü

2015

Int J Adv Manuf Technol

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Single point incremental forming (SPIF) is a relatively new manufacturing process that has been recently used to form medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. Prior work on accuracy characterization has shown that feature behavior is important in predicting accuracy. In this study, a set of basic geometric shapes consisting of ruled and freeform features were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions using multivariate adaptive regression splines (MARS) are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, distance to feature borders, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case where the curvatures in the part lie between that of ruled features and freeform features. It is shown that a mixed-MARS response surface model using a weighted average of the ruled and freeform surface models can be used for such a case to improve the mean prediction accuracy within ±0.5 mm. The predicted deviations show a reasonable match with the actual formed shape for the implant case and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants.

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Process window enhancement for single point incremental forming through multi-step toolpaths

Cited by 181 publications

References 10 publications

Damage prediction in single point incremental forming using an extended Gurson model

Damage prediction in single point incremental forming using an extended Gurson model

An efficient method for thickness prediction in multi-pass incremental sheet forming

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

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