The effect of partially cut-out blanks on geometric accuracy in incremental sheet forming

Allwood, Julian M.; Braun, Daniel; Music, Omer

doi:10.1016/j.jmatprotec.2010.04.008

Cited by 77 publications

(26 citation statements)

References 10 publications

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“…The backing plate shown in Figure 1.a is needed to decrease springback effects during forming. The springback phenomenon can also be avoided using a compensatory algorithm (Allwood et al, 2010). In any case, the opposite surface does not contact with any die or support.…”

Section: Figure 1 -Asymmetric Incremental Sheet Forming Variantsmentioning

confidence: 99%

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Sena

Lequesne²,

Duchêne

et al. 2016

Engineering Computations

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Single Point Incremental Forming (SPIF) is a dieless manufacturing process in which a sheet is deformed by using a tool with a spherical tip. This dieless feature makes the process appropriate for rapidprototyping and allows for an innovative possibility to reduce overall costs for small batches, since the process can be performed in a rapid and economic way without expensive tooling. As a consequence, research interest related to SPIF process has been growing over the last years.Numerical simulation of SPIF process can be very demanding and time consuming, mainly due to the the high non-linearity and constantly changing contact conditions between the tool and the sheet surface, as well as the nonlinear material behavior combined with non-monotonic strain paths. To reduce the simulation time, in the present work an adaptive remeshing technique is proposed being implemented in the in-house implicit finite element code LAGAMINE. This remeshing technique automatically refines only a portion of the sheet mesh at the tool's vicinity, therefore following the tool's motion. As a result, uniformly refined meshes required for accuracy purposes are avoided and consequently, the total CPU time can be drastically reduced.In this work, the proposed automatic refinement technique is applied developed within a Reduced Enhanced Solid-Shell (RESS) framework to further improve numerical efficiency. Finally, validations by means of benchmarks are carried out, with comparisons against experimental results. Keywords

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Section: Figure 1 -Asymmetric Incremental Sheet Forming Variantsmentioning

confidence: 99%

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Sena

Lequesne²,

Duchêne

et al. 2016

Engineering Computations

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“…Allwood et al [11] reported that the specification of geometric accuracy from industrial users for metal sheet components are typically within ±0.2 mm over the whole surface of a part, while the geometric error for ISF currently only achieved around ±3 mm. They [12] also summarized the geometric accuracy in the ISF process into three definitions, i.e. (a) clamped accuracy, (b) unclamped accuracy and (c) final accuracy.…”

Section: Geometric Accuracymentioning

confidence: 99%

Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

Daniel

et al. 2015

Int J Adv Manuf Technol

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Incremental sheet forming (ISF) is a promising manufacturing process that features benefits of reduced forming forces, enhanced formability and greater process flexibility. It also has a great potential to achieve economic payoff for rapid prototyping applications and for small quantity production in various applications. However, limited research has been conducted from the sustainability point of view, particularly for energy consumption. More consumed energy will generate more heat and affect tool and product wear. Also, geometric accuracy is still one of the dominant limits for the further development and commercialization of the ISF technology. Therefore, the aim of this study is to investigate how different process parameters affect the consumed energy during the forming process and also find the optimal working condition for lower deformation energy with higher geometric accuracy. A Box-Behnken design of 27 tests for pyramidforming processes have been performed for a multi-objective optimisation that considers four factors: step down, sheet thickness, tool diameter and wall angle at three levels. The deformation energy during the forming process was calculated based on the measured forming forces. It was found that the deformation energy heavily depends on the sheet thickness because of higher plastic energy required to deform the material. Increasing step-down size within a limited range or decreasing the wall angle is also an effective approach to reduce the deformation energy. Moreover, the effects of various process parameters on the global geometric accuracy have also been investigated. The geometric error has been empirically predicted by quadratic equations giving the influence of the most influential forming parameters. It was concluded that the geometric quality is largely determined by the quadratic effect of wall angle, the linear effect of sheet thickness and the interaction effect of thickness and step down. Finally, the optimal working conditions for both independent and simultaneous minimisation of deformation energy and geometric error during the pyramid-forming process are provided.

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“…In order to improve the poor geometric accuracy, some attempts have been presented in the literature, including experimental investigation of process parameters [4,6], hybrid ISF processes [7][8][9], the use of partially cut-out blanks [10], and a multi-stage strategy [3]. Recently, many studies concentrated on the toolpath correction/optimisation.…”

Section: Introductionmentioning

confidence: 99%

Part accuracy improvement in two point incremental forming with a partial die using a model predictive control algorithm

Kearney

Wang

et al. 2017

Precision Engineering

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.Part accuracy improvement in two point incremental forming with a partial die using a model predictive control algorithm.Precision Engineering http://dx.doi.org/10. 1016/j.precisioneng.2017.02.006 This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. Research highlights: Flexible forming technologies are becoming increasingly significant with the rise of small batch and customised production in the market. work. The enhanced control algorithm is able to correct the toolpath in both the vertical and horizontal directions. In the newly-added horizontal control module, intensive profile points in the evenly distributed radial directions of the horizontal section were used to estimate the horizontal error distribution along the horizontal sectional profile during the forming process. The toolpath correction was performed through properly adjusting the toolpath in two directions based on the optimised toolpath parameters at each step. A case study for forming a non-axisymmetric shape was conducted to experimentally validate the developed toolpath correction strategy. Experiment results indicate that the two-directional toolpath correction approach contributes to part accuracy improvement in TPIF compared with the typical TPIF process that is without toolpath correction.

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The effect of partially cut-out blanks on geometric accuracy in incremental sheet forming

Cited by 77 publications

References 10 publications

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

Part accuracy improvement in two point incremental forming with a partial die using a model predictive control algorithm

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