Abstract
Incremental Forming, IF technology is a method for producing complex 3D-dimensional sheet profiles. Compared to conventional forming process, IF has some advantages, such as the punch-die set product deformation is not necessary, lower tools cost, shorter time prototype production, flexibility. The accuracy of the incremental forming products is still lower than those produced by the conventional forming process. One of the main parts of the IF tools-set is the supporting tools. The product profile accuracy limits the simplicity or complexity of the supporting tools. When the product profile does not contain a horizontal surface, the simple supporting tool can be used. If the product profile is more complex, the supporting tools should include more details. The present work introduces the effect of supporting plate radiuses in SPIF, Single Point Incremental Forming process. The supporting plate is used to investigate the effect of springback during the forming process. Aluminum sheet metals (A1025) are used for manufacturing the products. The study objective is to understand the springback behavior, which is affected by supporting tools. The strain distributions of the final deformed product section at each step size have been analyzed and evaluated in detail.
Highlights
Incremental Forming, IF process is a quite recent technology for manufacturing applications and has some drawbacks: a) the product precision is limited (-1 mm thickness); b) the lubrication is essential, due to the direct contact, heat is generated; c) the surface finish is reduced; and d) the mass production is low [1].The limitations of IF processes are that the dimensional precision of the deformed products are affected by the springback effect [2].The IF forming process applications are appreciated in terms of dimensional accuracy to lower than 1 mm tolerance [3]
The highest appears to be a good indication to evaluate the failure of success of the deformed product
The results show that increasing the supporting plate radius with respect to the supporting space to total free blank ratio gives good results for reducing the springback effect
Summary
Incremental Forming, IF process is a quite recent technology for manufacturing applications and has some drawbacks: a) the product precision is limited (-1 mm thickness); b) the lubrication is essential, due to the direct contact (forming tool-blank), heat is generated; c) the surface finish is reduced; and d) the mass production is low [1]. The investigators studied this matter and they recommended several proposals to develop the geometrical accuracy of IF products: - use backing plate for supporting the blank edges [3, 5]; - reduce the springback by selecting the forming tool radius and step size as small as possible [6,7]; - minimize the springback effect by using multi pass during the forming trajectory [5], as the springback increases when the number of stages increases as indicated by [8]; - reduce the springback by adjusting the dimensional precision and correcting the toolpath "in-process" [9], or "out-process”; the divergences of the deformed product from the CADmodel were measured [3, 10]; - the springback deviation from the finite element analysis, FEA and the CAD-model is defined and redefined to improve the forming tool strategy [10]; - new algorithm based on the toolpath is presented by [11]; - various models are proposed to solve accuracy problems by using flexible systems with high complexity [12]; - use local heat by laser assisted or heating the total blank before the forming process to improve formability during IF process [13,14]. Aluminum (A1025) alloy sheets to deform a product with a frustum cone geometry using a supporting plate (with 1-20 mm radius) are used
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