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Manufacture of Bead-Stiffened Panels Using the Single Point Incremental Sheet Forming Technique

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Krasowski B. , Kubit A. , Trzepieciński T. , Slota J.

Archives of Metallurgy and Materials

2022

tom Vol. 67, iss. 4

1305--1314

This paper presents the results of experimental research on the fabrication of thin-walled panels with longitudinal stiffening ribs by the single point incremental sheet forming technique. The bead-stiffened panels were made of Alclad 2024-T3 aluminium alloy sheets commonly used in aircraft structures. The influence of forming parameters and tool strategy on surface quality and the possibility of obtaining stiffening ribs with the required profile and depth was tested through experimental research. Two tool path strategies, spiral with continuous sinking and multi-step z-level contouring, were considered. The results of the experiments were used to verify the finite element-based numerical simulations of the incremental forming process. It was found that the main parameter which influences the formability of test sheets is the tool path strategy; the tool path strategy with multi-step z-level contouring allowed the rib to be formed to a depth of 3.53 mm without risk of cracking. However a greater depth of rib equal of 5.56 mm was achieved with the continuous tool path. The tool path strategy was also the main parameter influencing the surface finish of the drawpiece during the single point incremental forming process.

Application of X-ray Diffraction for Residual Stress Analysis in Truncated Cones Made by Incremental Forming

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Krasowski B. , Kubit A. , Trzepieciński T. , Dudek K. , Slota J.

tom Vol. 14, no 2

103--111

The final accuracy of the parts formed using single point incremental forming greatly depends on the mechanical properties of the material to be formed and the residual stress formation. In this paper, an X-ray diffraction technique was used to study the distribution of the residual stress along the generating line of the conical drawpiece. A DC04 steel sheet with a thickness of 0.8 mm was used as a test material. The basic mechanical properties of the DC04 sheet metal were determined in the uniaxial tensile test according to the EN ISO 6892–1:2016. It was found that the maximum amount of the residual stress existed in a point located in the midway between a base and a truncation of the drawpiece. In the outer surface of the drawpiece, the orange peel defect associated with a rough surface appearance after SPIF a drawpiece, was observed. In contrast, the inner surface of component was characterized by linear grooves associated with the interaction of tool tip with the sheet surface. This defect is mainly influenced by vertical step size.