Abstract
Incremental forming is one of the most well-known forming processes for complex and asymmetric parts. This method uses a CNC machine, simple forming tool, and a die. This study focused on effects of some parameters such as the material, feed rate, pitch, rotational speed and movement strategy of tool on the dimensional precision, forming force, thickness distribution and fracture in the welding area. The results showed that single point incremental forming (SPIF) led to a better thickness distribution with lower tool force, whereas two-point incremental forming led to better dimensional accuracy. Rotational speed does not have any significant impact on the forming process while decreasing the feed rate partially reduced the forming force. According to the results, although dimensional precision in double point incremental forming is better than SPIF, when it comes to the thickness distribution, forming force, and economic issues, SPIF is in favor. The results also showed that by connecting two materials, different parameters for the two materials could be investigated simultaneously in one simulation process.
Highlights
In this fast-paced world, it is reasonable for the industry to seek fast, economical, and high quality approaches for forming parts
This paper presents the effects of being two-materialrectangular ring on the dimensional precision, thickness distribution, forming force, and fracture in the welding regions and the sheet by changing parameters, which has not been completely evaluated in the previous researches
The tool path was spiral for all movement strategies, 3.1.2 Rotational speed
Summary
In this fast-paced world, it is reasonable for the industry to seek fast, economical, and high quality approaches for forming parts. Asghari et al [14] examined the effects of parameters of DPIF, such as tool nose diameter, wall angle, rotational speed and deep step, on the minimum thickness, surface quality, and spring-back. Suresh et al [22] have overcome the disadvantages of SPIF in forming some certain angles by introducing a number multi-stage incremental forming methods As a result, they could form cylindrical, spherical and square shapes with critical angles. Mirnia et al [28] studied the ductile damage behavior of cones made of Al alloys formed using three two-step incremental forming approaches They investigated the parameters which affected the failure analysis. Parameters which affect the four mentioned properties are: movement strategy of the tool, whether to use SPIF or DPIF approach, rotational speed, feed rate, pitch size and sheet material. Geometry of a pyramidal ring, with an inner and outer wall, will lead to a better study
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