Review on multi-stage incremental forming process to form vertical walled cup

Vignesh, G.; Pandivelan, C.; Narayanan, C. Sathiya

doi:10.1016/j.matpr.2019.09.116

Cited by 11 publications

(8 citation statements)

References 27 publications

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“…On the side wall of the experimental part (in the horizontal axis are (4,17) and (50,67)), the thickness will become thinner with the increase in forming depth. The thickness of areas (in the horizontal axis are (10,14) and (55,59)) will increase because the two areas (10,14) and (55,59) are near the overturned surface.…”

Section: Thickness Distributionmentioning

confidence: 99%

“…For straight-wall parts, a multistage forming method is proposed. That is, the straight-wall part is realized through multistage forming with a forming angle less than the forming limit angle [10]. At present, research on multistage incremental forming is mainly carried out from two aspects: positive incremental forming and negative incremental forming.…”

Section: Introductionmentioning

confidence: 99%

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Research on the Negative Multistage Incremental Forming of Straight-Wall Parts Based on the Extrusion from the Forward and Reverse Side of the Sheet

Cheng

Zhu

Jung

2022

Metals

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Because the forming area involved in traditional reverse multistage incremental forming is only located inside the model, the sheet-metal thinning rate is relatively large. Particularly, the straight-wall parts with a narrow internal space cannot be formed using traditional multistage incremental forming. Therefore, a negative multistage incremental forming that extrudes the sheet from the forward and the reverse side of the straight-wall part is proposed in this paper. In this method, firstly, the auxiliary surface is generated to divide the straight-wall part model into three forming regions; secondly, the first- and second-stage forming are carried out from the forward side of the straight-wall part with support, respectively; Thirdly, the third-stage forming is carried out from the forward side of the straight-wall part without support. The software system for auxiliary-surface generation, the straight-wall parts partition, each intermediate-stage-forming model, and each stage-forming toolpath generation was developed by using C++, VC++, and OpenGL library. In order to verify the feasibility of the proposed method in this paper, the forming experiments of a 1060 aluminum sheet were conducted using traditional reverse multistage forming and the proposed method in this paper, and the forming effects were compared and analyzed. The results show that compared with traditional reverse multistage incremental forming with forward-side extrusion, the multistage incremental forming method with the forward and the reverse-sided extrusion proposed in this paper can increase the area of the sheet participating in the deformation and avoid the problem of excessive thinning of sheet thickness, especially suitable for the straight-wall part model with narrow internal space.

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Section: Thickness Distributionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Research on the Negative Multistage Incremental Forming of Straight-Wall Parts Based on the Extrusion from the Forward and Reverse Side of the Sheet

Cheng

Zhu

Jung

2022

Metals

View full text Add to dashboard Cite

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“…Nirala et al [10] eliminated stepped features during multi-stage forming using experiments. Vignesh et al [11] investigated the geometric accuracy of formed parts, including dimensional deviation and step formation at the base, the effect of forming direction and strategy, the formability of formed parts using the Forming Limit Stress Diagram (FLSD) and thickness distribution, and comparisons of the MSPIF process. Lingham et al [12] predicted that rigid body displacement is based on the tool path and variation in the profiles of produced components, while sheet thickness is determined by tool and sheet deflections generated by forces acting on them.…”

Section: Introductionmentioning

confidence: 99%

Improving the formability during ultrasonic-assisted multi-stage incremental sheet forming

Ghafoor

Zhao

et al. 2022

IOP Conf. Ser.: Mater. Sci. Eng.

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Multi-stage sheet forming is an encouraging technique to obtain complex geometries by change of the design of intermediate stages. Due to the occurrence of stepped feature during multi-stage forming, the final geometry shape is affected and the formability is deteriorated. To eliminate fracture and enhance formability, ultrasonic assistance is integrated with the multi-stage sheet forming process. The present work aims to investigate the effect of ultrasonic-vibrations (UV) on formability and thickness evolution using two multi-stage strategies through experiments. A frequency of 29 kHz and an amplitude of 10 μm are taken for the ultrasonic-assisted incremental forming process. Firstly, two distinct strategies are compared by experiments. Secondly, thorough investigation of formability experiments is performed by applying the UV at only one or two stages instead of the complete multi-stage forming process. The results show that formability of the part is increased while applying UV at intermediate stages. Similarly, it is confirmed that UV is more advantageous during latter stage of experiment. This work provides an effective strategy to improve the formability of the incremental sheet forming process by using the ultrasonic vibrations in a smart way.

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“…In order to solve the problem of the straight wall parts forming, many scholars proposed to add intermediate forming stages on the basis of the single stage forming to improve the formability of the single stage forming, that is, the multi-stage forming [8]. The research results show that the number of intermediate forming stages, forming toolpath, forming strategy, and forming direction Materials 2021, 14, 4818 2 of 20 of the multi-stage forming have influence on the thickness distribution and geometric accuracy of the straight wall parts [9].…”

Section: Introductionmentioning

confidence: 99%

Toolpath Planning and Generation for Multi-Stage Incremental Forming Based on Stretching Angle

2021

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To solve the problems that exist in the multi-stage forming of the straight wall parts, such as the sheet fracture, uneven thickness distribution, and the stepped feature sinking, a new forming toolpath planning and generation method for the multi-stage incremental forming was proposed based on the stretching angle. In this method, the parallel planes that were used for forming toolpath generation were constructed by using the stretching angle so that the distances between the parallel planes and the forming angles were gradually reduced. This makes the sheet material flow become changed and the thickness thinning is relieved. The software system for the toolpath generation was developed by using C++, VC++, and OpenGL library. In order to verify the feasibility of the proposed method, numerical simulation and forming experiments were carried out for the single stage forming, the traditional multi-stage forming, and multi-stage forming based on the proposed forming toolpath, using 1060 aluminum sheets. The comparative analysis of the thickness distribution, profile curve, strain curve, and sheet material flow shows that the proposed method is feasible, and the profile dimension accuracy is better, the thickness distribution is more uniform, and the sinking and bulging are significantly reduced. The formed sheet part with the stretching angle of 15° has higher dimensional accuracy, smaller bottom subsidence, and larger thickness than that of the stretching angle 5°.

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Review on multi-stage incremental forming process to form vertical walled cup

Cited by 11 publications

References 27 publications

Research on the Negative Multistage Incremental Forming of Straight-Wall Parts Based on the Extrusion from the Forward and Reverse Side of the Sheet

Research on the Negative Multistage Incremental Forming of Straight-Wall Parts Based on the Extrusion from the Forward and Reverse Side of the Sheet

Improving the formability during ultrasonic-assisted multi-stage incremental sheet forming

Toolpath Planning and Generation for Multi-Stage Incremental Forming Based on Stretching Angle

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