Rapid prototyping of aircraft canopy based on the incremental forming process

Barimani-Varandi, Abozar; Nasrabadi, Mohammad Kazemi; Ravan, Bahram Abedi; Javadi, M.

doi:10.1007/s40430-021-02811-1

Cited by 11 publications

(4 citation statements)

References 31 publications

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“…Thus, SPIF has greater potential in the aspects of rapid prototype manufacturing as well as small batch production [1,2]. SPIF can fulfil the current requirements for flexible, feasible, sustainable, and economic manufacturing technology for personalized sheet metal parts, small-batch prototypes, and customized products without the use of expensive specialized machines or equipment [3][4][5].…”

Section: Introductionmentioning

confidence: 99%

The Formability of Perforated TA1 Sheet in Single Point Incremental Forming

Wang

Feng

2023

Materials

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In light of the analysis on the single point incremental forming (SPIF) principle of perforated titanium sheet and the corresponding peculiarities during the forming process, it is found that the wall angle constitutes the pivotal parameter influencing the SPIF quality of the perforated titanium sheet, and this is also the key evaluation index to test the application of SPIF technology on a complex surface. This method for integrating the experiment and the finite element modelling was utilized in this paper to study the wall angle range and fracture mechanism of Grade 1 commercially-pure α titanium (TA1) perforated plate, plus the effect of different wall angles on the quality of perforated titanium sheet components. The forming limiting angle, fracture, and deformation mechanism of the perforated TA1 sheet in the incremental forming were obtained. In accordance with the results, the forming limit is related to the forming wall angle. When the limiting angle of the perforated TA1 sheet in the incremental forming is around 60 degrees, the fracture mode is the ductile fracture. Parts with a changing wall angle have a larger wall angle than parts with a constant angle. The thickness of the perforated plate formed part does not fully satisfy the sine law, and the thickness of the thinnest point of the perforated titanium mesh with different wall angles is lower than that predicted by the sine law; therefore, the actual forming limit angle of the perforated titanium sheet should be less than that predicted by a theoretical calculation. With the increase in the forming wall angle, the effective strain, the thinning rate, and the forming force of the perforated TA1 titanium sheet all increase, while the geometric error decreases. When the wall angle of the perforated TA1 titanium sheet is 45 degrees, the parts with a uniform thickness distribution and good geometric accuracy can be obtained.

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Section: Introductionmentioning

confidence: 99%

The Formability of Perforated TA1 Sheet in Single Point Incremental Forming

Wang

Feng

2023

Materials

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“…Due to the advantages of polymeric materials on the one hand and of the SPIF process on the other, SPIF-processed parts have a wide application in a variety of fields. For example, the canopy of various aircraft can be obtained from polycarbonate sheets [ 28 ] or the hole flange can be obtained from polyethylene terephthalate [ 29 ]. Polymer parts manufactured by SPIF have recently found application in the medical device and medical prosthesis industries [ 30 , 31 ].…”

Section: Introductionmentioning

confidence: 99%

Minimizing the Main Strains and Thickness Reduction in the Single Point Incremental Forming Process of Polyamide and High-Density Polyethylene Sheets

et al. 2023

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Polymeric materials are increasingly used in the automotive industry, aeronautics, medical device industry, etc. due to their advantage of providing good mechanical strength at low weight. The incremental forming process for polymeric materials is gaining increasing importance because of the advantages it offers: relatively complex parts can be produced at minimum cost without the need for complex and expensive dies. Knowing the main strains and especially the thickness reduction is particularly important as it directly contributes to the mechanical strength of the processed parts, including in operation. For the design of experiments, the Taguchi method was chosen, with an L18 orthogonal array obtained by varying the material on two levels (polyamide and polyethylene) and the other three parameters on three levels: punch diameter (6 mm, 8 mm and 10 mm), wall angle (50°, 55° and 60°) and step down (0.5 mm, 0.75 mm and 1 mm). The output parameters were strain in the x direction, strain in the y direction, major strain, minor strain, shear angle and thickness reduction. Two analyses were conducted: signal-to-noise ratio analysis with the smaller-is-better condition and analysis of variance. The optimum values for which the thickness was reduced were the following: wall angle of 50°, punch diameter of 10 mm and step down of 0.75 mm.

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“…It is based on the use of a spherical punch, which moves along Computer Numerical Control (CNC) or robots-controlled trajectories similar to those of machining [2] and useful to manufacture customized products [3]. The use of robot arms can significantly reduce the manufacturing time and it is possible to deform, bend, flange, and load/unload the part with the same fixture [4].…”

Section: Introductionmentioning

confidence: 99%

“…Single-Point Incremental Forming (SPIF) is done using a single tool and no need for tailored tools and dies [4][5][6]. The major parameters in SPIF have been identified, and process capabilities are being expanded [7,8].…”

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confidence: 99%

Accuracy and Sheet Thinning Improvement of Deep Titanium Alloy Part with Warm Incremental Sheet-Forming Process

Saidi

Moreau

Cherouat

et al. 2021

JMMP

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Incremental forming is a recent forming process that allows a sheet to be locally deformed with a hemispherical tool in order to gradually shape it. Despite good lubrication between the sheet and the tip of the smooth hemisphere tool, ductility often occurs, limiting the formability of titanium alloys due to the geometrical inaccuracy of the parts and the inability to form parts with a large depth and wall angle. Several technical solutions are proposed in the literature to increase the working temperature, allowing improvement in the titanium alloys’ formability and reducing the sheet thinning, plastic instability, and failure localization. An experimental procedure and numerical simulation were performed in this study to improve the warm single-point incremental sheet forming of a deep truncated cone in Ti-6Al-4V titanium alloy based on the use of heating cartridges. The effect of the depth part (two experiments with a truncated cone having a depth of 40 and 60 mm) at hot temperature (440 °C) on the thickness distribution and sheet shape accuracy are performed. Results show that the formability is significantly improved with the heating to produce a deep part. Small errors are observed between experimental and theoretical profiles. Moreover, errors between experimental and numerical displacements are less than 6%, which shows that the Finite Element (FE) model gives accurate predictions for titanium alloy deep truncated cones.

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Rapid prototyping of aircraft canopy based on the incremental forming process

Cited by 11 publications

References 31 publications

The Formability of Perforated TA1 Sheet in Single Point Incremental Forming

The Formability of Perforated TA1 Sheet in Single Point Incremental Forming

Minimizing the Main Strains and Thickness Reduction in the Single Point Incremental Forming Process of Polyamide and High-Density Polyethylene Sheets

Accuracy and Sheet Thinning Improvement of Deep Titanium Alloy Part with Warm Incremental Sheet-Forming Process

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