Abstract
Single Point Incremental Forming (SPIF) is a flexible and economic manufacturing process with a strong potential for manufacturing small and medium batches of highly customized parts. Formability and failure in SPIF have been intensively discussed in recent years, especially because this process allows stable plastic deformation well above the conventional forming limits, as this enhanced formability is only achievable within a certain range of process parameters depending on the material type. This paper analyzes formability and failure of AISI304-H111 sheets deformed by SPIF compared to conventional testing conditions (including Nakazima and stretch-bending tests). With this purpose, experimental tests in SPIF and stretch-bending were carried out and a numerical model of SPIF is performed. The results allow the authors to establish the following contributions regarding SPIF: (i) the setting of the limits of the formability enhancement when small tool diameters are used, (ii) the evolution of the crack when failure is attained and (iii) the determination of the conditions upon which necking is suppressed, leading directly to ductile fracture in SPIF.
Highlights
Incremental Sheet Forming (ISF) processes accomplish the current requirements for rapid, adaptive, economic and environmentally friendly manufacturing
This research work revisits formability and failure of AISI304 sheets deformed by single point incremental forming
Formability in Single Point Incremental Forming (SPIF) has been compared to conventional testing conditions, including Nakazima and stretch-bending
Summary
Incremental Sheet Forming (ISF) processes accomplish the current requirements for rapid, adaptive, economic and environmentally friendly manufacturing. Considering that for a certain range of process parameters corresponding to high t0 /R ratios failure will occur without previous necking in SPIF, Isik et al [11] proposed a new methodology to determine the maximum strains at fracture directly from the in-plane strain measurements without evaluating the gauge length strains, which simplifies the procedure for obtaining the FFL. This proposal involves using a truncated lobe conical shape with varying wall angle and measuring the in-plane strains at fracture, avoiding the need to measure gauge length strains, which is required with typical test specimens (in-plane torsion and plane shear tests) In this scientific framework for SPIF, this paper allows the authors presenting the following contributions to the current state of the art in ISF regarding the SPIF process applied to AISI304-H111 sheets: (i) the setting of the limits of the formability enhancement when small tool diameters are used,.
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