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Improve Single Point Incremental Forming Process Performance Using Primary Stretching Forming Process

100%

Bedan A. S. , Shabeeb A. H. , Hussein E. A.

tom Vol. 17, no 5

260--268

Incremental forming (IF) is one of the sheet metals forming technique where is a sheet formed into a final workpiece using a series of small incremental sheet deformations. In Incremental sheet metal forming process, one of the important steps is to produce the forming part with acceptable performance such as product accurate and uniform thickness distribution with a homogenous grain distribution that consider as the main challenge of incremental sheet metal forming process. This work is carried out to find the best method to control the product performance of the final parts using a new method of applying a primary stretching forming process with a hemispherical forming tool followed by single point forming SPIF. Different primary forming depth (10, 20, 30 and 40 mm) were applied to find their effect on the forming behavior of the final product and compare them to the single point forming product without using a primary forming process. The experimental results showed the improvement in microstructure by applying SPIF process after primary stretching, with grain size of 36 µm at 40 mm forming depth as compared to 52 µm when using pure SPIF, a twining effects presence in both cases. A high improvement with a minimum dimension deviation of (6%) with respect to the forming process in single point incremental forming process without a primary forming process that result forming deviation equal to (11.6%) with respect to the desired design. The thickness distribution of the final product also improved by applying the primary stretching forming process before the SPIF process reaches to (6.9%, 9.1%, 14.9% and 21.5%) at forming depth (10, 20, 30 and 40) mm, respectively.

Experimental analysis of single point incremental forming of truncated cones in DC04 steel sheet

58%

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

tom Vol. 20, nr 4(66)

5--15

Experimental tests to form truncated cones were carried out on a 3-axis milling machine. 0.8-mm thick low-alloy DC04 steel sheets were used as test material. The profile tool-path trajectory was generated using the EDGECAM software. The slope angle and diameter of the base of the conical shaped drawpieces were 70°-72° and 65 mm, respectively. The drawpiece heights were up to 75 mm. The full synthetic lubricant 75W85 was used to reduce the frictional resistance. The effect of selected incremental forming parameters on the formability of the DC04 sheet and the susceptibility to crack formation have been analysed and discussed. It was found that the surface roughness of the workpiece is strongly influenced by step depth. By controlling the feed rate, it is possible to prevent failure of the material.