Abstract
During the single-point incremental forming (SPIF) process, a sheet is formed by a locally acting stress field on the surface consisting of a normal and shear component that is strongly affected by friction of the dragging forming tool. SPIF is usually performed under well-lubricated conditions in order to reduce friction. Instead of lubricating the contact surface of the sheet metal, we propose an innovative, environmentally friendly method to reduce the coefficient of friction by ultrasonic excitation of the metal sheet. By evaluating the tool-workpiece interaction process as non-linear due to large deformations in the metal sheet, the finite element method (FEM) allows for a virtual evaluation of the deformation and piercing parameters of the SPIF process in order to determine destructive loads.
Highlights
Robotized single-point incremental forming (SPIF), whereby a small-sized tool deforms a sheet of metal, is ideal for replacing expensive stamping processes, assuring flexibility and cost-effectiveness, as well as increasing the competitiveness of companies
The metal-sheet vibrational analysis, performed with the Polytec scanning vibrometer, PSV-500-3D-HV, presented in Figure 1, shows that in this frequency band, the workpiece is dominated by planar (XY) higher harmonic vibrations, which are significantly less suppressed in the tool-sheet pair friction contact than in direction Z, perpendicular to the metal sheet (Figure 6)
The measured surface roughness of the sheet formed without ultrasonic vibrations varied in the range of Ra = 0.30–0.33 μm, and with ultrasonic vibrations, surface roughness was in the range of Ra = 0.18–0.25 μm
Summary
Robotized single-point incremental forming (SPIF), whereby a small-sized tool deforms a sheet of metal, is ideal for replacing expensive stamping processes, assuring flexibility and cost-effectiveness, as well as increasing the competitiveness of companies. This technology opens up new possibilities compared to traditional small-series production methods wherein added value is determined by skill and qualification. Lubricating oil was found to produce a surface roughness close to Ra = 1.45 μm, which exceeds the surface roughness of an undeformed sheet and degrades the quality of the final product. As lubricants are not environmentally friendly, new methods for reducing and predicting forming forces need to be explored
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