Thermal modeling in electricity assisted incremental sheet forming

Min, Junying; Seim, Patrick; Störkle, Denis Daniel; Thyssen, Lars; Kuhlenkoetter, Bernd

doi:10.1007/s12289-016-1315-6

Cited by 24 publications

(5 citation statements)

References 24 publications

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“…To further increase the temperature for heat-assisted SPIF systems for high-strength materials, the studies [44][45][46] established analytical models to investigate the heating and deformation mechanism for the electric heating-assisted SPIF process. Meier and Magnus [47] and Möllensiep et al [48] developed direct current (DC) to the robotic arm-controlled tools to direct a temperature of 600 to the steel metal sheets.…”

Section: Electric Heating-assisted Single-point Formingmentioning

confidence: 99%

Heat-assisted incremental sheet forming for high-strength materials — a review

Attallah²,

Essa³

2022

Int J Adv Manuf Technol

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Single-point incremental forming (SPIF) is a sheet forming technique that deforms sheet materials incrementally to a designated shape. The process has shown high ability to deform low-strength materials for good geometrical accuracy and formability at room temperature. Deforming high-temperature alloys, such as high-strength steels and Ti-6AI-4 V, requires integrated heat sources to increase the ductility of the metal sheets for deformation. However, the integration of heating results in unpredictable thermal behaviours and impacts the formability, geometric accuracy, thickness distribution and surface quality. Considerable research efforts have invented different heating methods and designed novel tools and analytical modelling to resolve the limitations. The current challenge remains improving the localised and stable heating, functional tool design to reduce the thermal expansion and friction at the tool-surface contact area and the analysis of relationship between thermal and mechanical effects. This study aims to review the heating-assisted SPIF systems for high-strength alloy sheets to solve the current limitations. The method includes analysis of heating systems, tool, tool path design, lubricants and macro- and micro-numerical analyses. Additionally, the study aims to correlate the microstructural properties to the mechanical behaviours and subsequent effects on forming force, strain, springback, geometrical accuracy and surface quality.

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Section: Electric Heating-assisted Single-point Formingmentioning

confidence: 99%

Heat-assisted incremental sheet forming for high-strength materials — a review

Attallah²,

Essa³

2022

Int J Adv Manuf Technol

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“…The geometric profile of forming region is viewed as a cube due to the fact that the active time of currents is extremely short. According to the study of Min [21], the dV/dt is written as: 4), the resistance of material resistance is obtained according to the following expression:…”

Section: Electric-thermal Boundary Modelsmentioning

confidence: 99%

“…[6][7][8][9][10][11] In recent years, a series of studies are published on EHIF. [12][13][14][15][16][17][18][19][20][21] During electric hot incremental forming, some features, such as forming temperature, forming accuracy, and properties of material, change with forming process parameters in time and space. Therefore, the numerical method is more conducive to analyze the changing situation of characteristic variables, and more and more commercial software with higher computational efficiency is adopted to simulate the forming process of EHIF.…”

Section: Introductionmentioning

confidence: 99%

Numerical prediction of Joule heating effect in electric hot incremental sheet forming

Zhang

et al. 2022

Int J Adv Manuf Technol

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Since the deformation region involves the interaction of electric-thermal-force coupling in electric hot incremental sheet forming, the numerical simulation of the forming process is unusually difficult. Currently, the thermal-force coupling method is adopted to simulate approximately the whole forming process, and the Joule heating effect is often ignored. Therefore, the numerical simulation of Joule heating effect is especially significant for the prediction accuracy of forming process. In this paper, a novel numerical simulation method, considering electric-thermal-force parameters, was proposed to instantly update the thermal-force condition of forming region. Meanwhile, the model of contact thermal conductance was established combining geometrical and electric-thermal parameters, and then a high-precision finite element model was obtained to predict the Joule heating effect of forming region. In addition to this, the effect of thermal superposition on forming temperature was further analyzed and a modified model of contact thermal conductance was established in electric hot incremental sheet forming.

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“…Due to the point contact characteristic of electric hot incremental forming, the forming tool and the sheet are set as electrodes respectively, and the arc burn defect of part surface is caused due to the contact loss between the tool and the sheet, thus making the whole forming process failure [10]. Although Skjoedt [12] and Shi [13] separately proposed design methods of high-precision machining path to solve the contact loss caused by structural characteristics of parts, the initial contact loss from the non-uniform stress distribution of forming regions is still a key problem restricting the development of electric hot incremental forming.…”

Section: Introductionmentioning

confidence: 99%

Improvement of arc burn defect of initial contact loss of electric hot incremental sheet forming

Sun

et al. 2022

Mechanics & Industry

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Electric hot incremental sheet forming, which is used to form hard-to-form sheet metal, is viewed as the one of rapid prototyping manufacturing technologies. However, the non-uniform stress distribution of forming regions would cause an initial contact loss phenomenon between the tool and the sheet, and an electric arc burn of the part surface is obtained due to the contact loss. In this work, a control method of axial pressure response was proposed to judge the stability of the initial contact between forming the tool and the sheet. A power supply on-off device was designed for electric hot incremental forming, and the calculation model of the initial axial force was established during deformation. Meanwhile, two response pressure values were proposed to control the power supply starting and the current intervention and to ensure the stability of the power supply during the forming process. In addition to this, the axial force and the surface of part were analyzed further in electric hot incremental sheet forming.

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Thermal modeling in electricity assisted incremental sheet forming

Cited by 24 publications

References 24 publications

Heat-assisted incremental sheet forming for high-strength materials — a review

Heat-assisted incremental sheet forming for high-strength materials — a review

Numerical prediction of Joule heating effect in electric hot incremental sheet forming

Improvement of arc burn defect of initial contact loss of electric hot incremental sheet forming

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