Abstract
Single Point Incremental Forming (SPIF) is a flexible process to manufacture sheet metal parts that is well adapted and profitable for prototypes or small batch production. Compared to traditional sheet forming technologies this relatively slow process can be used in different applications in automotive and aircraft industries, in architecture engineering and in medical aids manufacturing. In this paper indirectly obtained axial forming force on SPIF of variable wall angle geometry were studied under different process parameters. The estimation of the forces on AlMn1Mg1 sheets with 0.22 mm initial thickness is performed by continuous monitoring of servo motor currents. The deformation states of the formed parts were analysed using the ARGUS optical strain measurement system of GOM, while the roughness measurements were carried out by a System of Mitutoyo. Some initial Finite Element Analysis simulations and a crack monitoring method together with an interaction plot of forming speed, incremental depth, tool diameter and lubrication were also reported.
Highlights
Incremental sheet metal forming, with its main variants Single-Point Incremental Forming (SPIF) and Two-Point Incremental Forming (TPIF), is an interesting research topic in material science due to the extreme and complex mode for deformation, the flexibility of the process, and the high forming limits compared to traditional forming processes
Several articles have dealt with experimental study on force measurements for SPIF, like [1] or [2], but only a couple of them focus on sheets with an initial thickness of less than 0.5mm ([3]-[6])
As Gatea et al [7] highlighted regarding the Fracture Forming Limit Curve (FFLC) in a review, further investigation should be carried out concerning the effect of initial sheet thickness on the tool radius ratio (t0/R) on the FFLC and whether it is enough to describe FFLC in SPIF
Summary
Incremental sheet metal forming, with its main variants Single-Point Incremental Forming (SPIF) and Two-Point Incremental Forming (TPIF), is an interesting research topic in material science due to the extreme and complex mode for deformation, the flexibility of the process, and the high forming limits compared to traditional forming processes. Several articles have dealt with experimental study on force measurements for SPIF, like [1] or [2], but only a couple of them focus on sheets with an initial thickness of less than 0.5mm ([3]-[6]). As Gatea et al [7] highlighted regarding the Fracture Forming Limit Curve (FFLC) in a review, further investigation should be carried out concerning the effect of initial sheet thickness on the tool radius ratio (t0/R) on the FFLC and whether it is enough to describe FFLC in SPIF. The abovementioned factors and statements inspired this study to conduct experiments on AlMn1Mg1 sheets with an initial thickness of 0.22 mm and to run some preliminary numerical simulations with the given process parameters. The first part of this paper focuses on the material characterisation, introducing a Forming Limit Curve (FLC) measured by the Nakazima test and some numerical simulation results. Been investigated experimentally with servomotor acquisitions, and a simplified crack monitoring system is introduced
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