Single point incremental forming (SPIF) is one of the most promising technologies for the manufacturing of sheet metal prototypes and parts in small quantities. Similar to other forming processes, the design of the SPIF process is a demanding task. Nowadays, the design process is usually performed using numerical simulations and virtual models. The modelling of the SPIF process faces several challenges, including extremely long computational times caused by long tool paths and the complexity of the problem. Path determination is also a demanding task. This paper presents a finite element (FE) analysis of an incrementally formed truncated pyramid compared to experimental validation. Focus was placed on a possible simplification of the FE process modelling and its impact on the reliability of the results obtained, especially on the geometric accuracy of the part and bottom pillowing effect. The FE modelling of SPIF process was performed with the software ABAQUS, while the experiment was performed on a conventional milling machine. Low-carbon steel DC04 was used. The results confirm that by implementing mass scaling and/or time scaling, the required calculation time can be significantly reduced without substantially affecting the pillowing accuracy. An innovative artificial neural network (ANN) approach was selected to find the optimal values of mesh size and mass scaling in term of minimal bottom pillowing error. However, care should be taken when increasing the element size, as it has a significant impact on the pillow effect at the bottom of the formed part. In the range of selected mass scaling and element size, the smallest geometrical error regarding the experimental part was obtained by mass scaling of 19.01 and tool velocity of 16.49 m/s at the mesh size of 1 × 1 mm. The obtained results enable significant reduction of the computational time and can be applied in the future for other incrementally formed shapes as well.

/pdf/finite-element-simplifications-and-simulation-reliability-in-h9n9dy0k.pdf

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

The aim of the present paper is that of conducting a study on the basis of which the optimal parameters for the manufacturing of polymer parts by means of the single point incremental forming process can be chosen in such a way that the process forces have minimum values. Two polymeric materials with a 3 mm thickness, polyamide and polyethylene, were chosen for the analysis. The other input parameters that were considered were: the punch diameter, the step on vertical direction and the wall angle. The Taguchi method was chosen for the design of experiments. Each of the input parameters, except for the material, were varied on three levels—for the punch diameter: 6 mm, 8 mm and 10 mm; for the step on vertical direction: 0.5 mm, 0.75 mm and 1 mm; and for the wall angle: 50°, 55° and 60°. Forces were measured in the three directions of the coordinate axes and the results were analyzed based on the signal-to-noise ratio and an analysis of variance with the aim of minimizing the values of the forces. Considering the input parameters analyzed, it was concluded that the forces are most influenced by the material, followed by the punch diameter, the step on vertical direction and the wall angle.

https://www.mdpi.com/1996-1944/15/18/6453/pdf?version=1663669565

Minimizing the Forces in the Single Point Incremental Forming Process of Polymeric Materials Using Taguchi Design of Experiments and Analysis of Variance

Change in geometry size and thinning rate in single-point incremental forming process of TA1 sheet: evaluation method and finite element analysis

Because the forming area involved in traditional reverse multistage incremental forming is only located inside the model, the sheet-metal thinning rate is relatively large. Particularly, the straight-wall parts with a narrow internal space cannot be formed using traditional multistage incremental forming. Therefore, a negative multistage incremental forming that extrudes the sheet from the forward and the reverse side of the straight-wall part is proposed in this paper. In this method, firstly, the auxiliary surface is generated to divide the straight-wall part model into three forming regions; secondly, the first- and second-stage forming are carried out from the forward side of the straight-wall part with support, respectively; Thirdly, the third-stage forming is carried out from the forward side of the straight-wall part without support. The software system for auxiliary-surface generation, the straight-wall parts partition, each intermediate-stage-forming model, and each stage-forming toolpath generation was developed by using C++, VC++, and OpenGL library. In order to verify the feasibility of the proposed method in this paper, the forming experiments of a 1060 aluminum sheet were conducted using traditional reverse multistage forming and the proposed method in this paper, and the forming effects were compared and analyzed. The results show that compared with traditional reverse multistage incremental forming with forward-side extrusion, the multistage incremental forming method with the forward and the reverse-sided extrusion proposed in this paper can increase the area of the sheet participating in the deformation and avoid the problem of excessive thinning of sheet thickness, especially suitable for the straight-wall part model with narrow internal space.

/pdf/research-on-the-negative-multistage-incremental-forming-of-1zm2h73m.pdf

Research on the Negative Multistage Incremental Forming of Straight-Wall Parts Based on the Extrusion from the Forward and Reverse Side of the Sheet

Single-point incremental forming (SPIF) has emerged as a cost-effective and rapid manufacturing method, especially suitable for small-batch production due to its minimal reliance on molds, swift production, and affordability. Nonetheless, SPIF’s effectiveness is closely tied to the specific characteristics of the employed sheet materials and the intricacies of the desired shapes. Immediate experimentation with SPIF often leads to numerous product defects. Therefore, the pre-emptive use of numerical simulations to predict these defects is of paramount importance. In this study, we focus on the critical role of the forming limit curve (FLC) in SPIF simulations, specifically in anticipating product fractures. To facilitate this, we first construct the forming limit curve for Al1050 sheet material, leveraging the modified maximum force criterion (MMFC). This criterion, well-established in the field, derives FLCs based on the theory of hardening laws in sheet metal yield curves. In conjunction with the MMFC, we introduce a graphical approach that simplifies the prediction of forming limit curves at fracture (FLCF). Within the context of the SPIF method, FLCF is established through both uniaxial tensile deformation (U.T) and simultaneous uniform tensile deformation in bi-axial tensile (B.T). Subsequently, the FLCF predictions are applied in simulations and experiments focused on forming truncated cone parts. Notably, a substantial deviation in fracture height, amounting to 15.97%, is observed between simulated and experimental samples. To enhance FLCF prediction accuracy in SPIF, we propose a novel method based on simulations of truncated cone parts with variable tool radii. A FLCF is then constructed by determining major/minor strains in simulated samples. To ascertain the validity of this enhanced FLCF model, our study includes simulations and tests of truncated cone samples with varying wall angles, revealing a substantial alignment in fracture height between corresponding samples. This research contributes to the advancement of SPIF by enhancing our ability to predict and mitigate product defects, ultimately expanding the applicability of SPIF in diverse industrial contexts.

Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of Al1050 Sheet Material

A comprehensive review in incremental forming on approaches of deformation analysis and surface morphologies

Real-time applications and novel manufacturing strategies of incremental forming: An industrial perspective

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A comprehensive review in incremental forming on approaches of deformation analysis and surface morphologies

Real-time applications and novel manufacturing strategies of incremental forming: An industrial perspective