Abstract
The paper presents a novel solution for improving the accuracy of the wall area of parts manufactured by single point incremental forming. Thus, a forming tool with a special design that works according to the principle of circumferential hammering is deployed, with a direct improving effect of the forming conditions and consequently of the dimensional accuracy of the part. The research is focused on an experimental study of frustum-of-cone shapes manufactured from sheet metal blanks of DC05 deep drawing steel of 1 mm thickness. A typical customary technological setup is used for the single point incremental forming process, without any additional elements, and two forming tools, a hemispherical and a special one, which use the circumferential hammering effect. Several preliminary tests using both tools were performed in order to prove that part accuracy can be significantly improved by using the circumferential hammering tool. The research was further expanded to investigate the influence on part wall dimensional accuracy of three factors: tool spindle speed, tool feed rate and part dimensional configuration. Using a full factorial plan of experiments the results of 32 test runs were processed. All parts were machined adequately, free of any material fracturing. Based on the achieved machining accuracy of the part walls, precision mathematical models were developed for the prediction of part dimensional accuracy in those areas. The mathematical models were validated by practice, as the predicted accuracies were matched by the experimental results.
Highlights
Single-point incremental forming (SPIF) is a very flexible forming process of sheet metal that does not require, for its implementation, a dedicated set of tools as is necessary in conventional processes [1]
Several preliminary tests using both tools were performed in order to prove that part accuracy can be significantly improved by using the circumferential hammering tool
Li et al [3] claim, following other studies, that most of the industrial applications for sheet metal parts generally require a geometric accuracy of ±0.2 mm, while the dimensional precision obtained for parts manufactured by incremental sheet forming (ISF) is generally around ±3 mm
Summary
Single-point incremental forming (SPIF) is a very flexible forming process of sheet metal that does not require, for its implementation, a dedicated set of tools as is necessary in conventional processes [1]. Another solution for part accuracy improvement is incremental forming assisted by ultrasonic vibration This technology was introduced by Mingshun et al [27] into SPIF, in order to change magnitude and distribution of the residual stress in the material induced by the vibrating forming tool, reducing the springback effect and increasing the radial accuracy of the part. New, stable and easy-to-implement solutions should be developed, such as to render this process attractive for industrial manufacturers For this propose this paper put forward a method for improving part accuracy by means of a special forming tool lenging in terms of costs, time, complexity and the necessary human resource wit proper technical training. For thi propose this paper put forward a method for improving part accuracy by means of special forming tool based on the hammering working principle, that doe6sofn2o4t requir additional technological setup and/or complex design and manufacturing strategies. In reference to itsInwroerfkerienngceprtoinictsipwleortkhiengnopvrienlcidpelesitghneendovtoeol dl epsriegsneendtetodoilnprtehsiesnpteadpienr this paper is further called ciicrsocIfnunuvmrertnhefefteierroercnenaantllilcaefeodl rthcmoairimicntusgmmwteofeororirlne.kngitnitagolophlar(imCnmcHipeTrl)ien, gwththeoionlelo(tCvheHelTad)ce,rswoignhniyleemdthCteoTaocslrtopanrneydsmsenfCotTerdstianndths ifsorpaper conventional foisrmfuirntgheBtoraoscilac.lalleldy, cthirecCumHTfehreans ttihael shaammemdeimrienngsitoonosl a(sCtHheTC),Tw, whiiltehtthhee adcisrtoinncytmionCtThasttathneds for Basically, cthoenCvCHeHnTtTiaochntaiavsletfhoheermasdainmpgreetsodeonimlt.setnwsoiopnasraalsletlhfleaCttTen, ewditshurtfhaecedsiastti6ncmtimondtihstaatntcheepositioned CHT active head spyBrmeamsseienctartislclaytlw,lytohtoeptCahrHeaplTleahlnaefsltahtthatteeninsecadlmudseuesdrftiahmceetsnoosailotanx6issm.aAsmctchoderidsCitnaTgn, ctwoeiFtphigoutshriteeisod3niaesndtidnc4t, idounritnhgat the symmetrically CtoHtTheacptilvaenehethadat pinrecsleundtesstwthoe ptoaorlalalexlisf.laAttcecnoerddisnugrftaoceFsigaut r6esm3manddist4a,nce positioned during a singlesyrmotmateiotrnic,aCllHy Ttohtehaed pgleaonme etthrayt einaclbuledsestwthoectiorcoul maxfeisr.enAticaclorhdaimngmteorinFgigures 3 and 4, cycles, meanindgutrhiantgthaesitnogollehriotstatthioenp, aCrtHwT ahlleamdatgeeroiaml ettwryicenwabitlhesittswaoctcivirecuhmeafderecinrt-ial hammering cumference. cycles, meaning that the tool hits the part wall material twice with its active head cir-
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