Abstract
Single Point Incremental Forming process (SPIF) is a modern forming technique of sheet material. Principles of the process are based on manufacturing by layers-two dimensions layers with step size depth of the tool path. The movement of a hemispherical forming tool is using Computer Numerical Control (CNC) machine to produce the profile of the final product. The description of the process is more complicated by highly nonlinear boundary conditions. The paper presents a study of the effect of the flat forming tool profile through FEA on SPIF that permits the modelling of complex product geometries, material behaviour and boundary conditions. The results showed that the model of simulation can predict the behaviour of contact tool-blank, and the accuracy of product.
Highlights
Single Point Incremental Forming (SPIF) is a flexible sheet metal forming process with potential for small production and for rapid forming tools
Numerical Control (NC) milling machine is used for execution of the product and the forming tool path is programmed by Computer Aided Manufacturing (CAM) software
The contact in case of the spherical profile case begins with a point, until the shape of the blank surface becomes identical to the forming tool edge profile shape, which occurs gradually, with increasing the depth, more precisely at final stroke
Summary
Single Point Incremental Forming (SPIF) is a flexible sheet metal forming process with potential for small production and for rapid forming tools. Disadvantages of SPIF process: long forming time when compared to deep drawing process, small-lot production, low accuracy of the geometry, high springback, in bending edges and convex radius areas [6]. The forming tool radius effect on accuracy and ability of SPIF deforming process is studied with wide ranges (between 2-25 mm) of radiuses of the round head. The interaction between the tool step size and sheet metal thickness was researched [7] They concluded that the maximum forming wall angle is influenced by this interaction. The effect of forming tool radius, step size, and speed of forming on the formability were studied [8]. The paper showed that the flat head forming tool required lower forming force, and can give a better accuracy of the product profile and formability than the others. A new type of evaluation was used - contact status distributions by Auto CAD application and FEA method to observe the behaviour of the entire blank surface and the forming tool surface
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