Advertisement

Robot-assisted incremental sheet metal forming under the different forming condition

  • Swagatika MohantyEmail author
  • Srinivasa Prakash Regalla
  • Y. V. Daseswara Rao
Technical Paper
  • 50 Downloads

Abstract

Incremental sheet metal forming (ISF) is an emerging technology where the sheet is deformed incrementally by a stylus tool using a predefined tool path. Higher formability and process flexibility as compared to conventional forming can be achieved by this process. However, forming steeper wall angle parts in single-stage forming has been a challenging task in ISF. In this work, a robotic manipulator has been used to manipulate sheet metal with respect to tool to form steeper wall angle parts in a single stage. Process parameters have been varied to investigate the fracture limit of the sheet at steep wall angle. Effect of part inclination and part rotation using the designed manipulator on the formability of the sheet has been investigated. Analytical investigation of the effect of parameters on forming force and formability has been discussed and later validated by numerical simulation and experiments. The results show that the formability of the sheet changes by varying these process parameters. Formability can be improved by changing the part inclination and part rotation.

Keywords

Single-stage incremental forming Robot-assisted incremental forming Tilting angle Rotational velocity Step interval Strain 

References

  1. 1.
    Callegari M, Gabrielli A, Palpacelli M-C, Principi M (2008) Incremental forming of sheet metal by means of parallel kinematics machines. J Manuf Sci Eng 130:54501.  https://doi.org/10.1115/1.2823064 CrossRefGoogle Scholar
  2. 2.
    Wang Y, Huang Y, Cao J, Reddy NV (2008) Experimental study on a new method of double side incremental forming. In: International manufacturing science and engineering conference collocated with the 3rd JSME/ASME international conference on materials and processing, pp 601–607.  https://doi.org/10.1115/msec_icmp2008-72279
  3. 3.
    Malhotra R, Cao J, Ren F et al (2011) Improvement of geometric accuracy in incremental forming by using a squeezing toolpath strategy with two Forming tools. J Manuf Sci Eng 133:61019.  https://doi.org/10.1115/1.4005179 CrossRefGoogle Scholar
  4. 4.
    Malhotra R, Cao J, Beltran M et al (2012) Accumulative-DSIF strategy for enhancing process capabilities in incremental forming. CIRP Ann Manuf Technol 61:251–254.  https://doi.org/10.1016/j.cirp.2012.03.093 CrossRefGoogle Scholar
  5. 5.
    Cui Z, Cedric Xia Z, Ren F et al (2013) Modeling and validation of deformation process for incremental sheet forming. J Manuf Process 15:236–241.  https://doi.org/10.1016/j.jmapro.2013.01.003 CrossRefGoogle Scholar
  6. 6.
    Golabi S, Khazaali H (2014) Determining frustum depth of 304 stainless steel plates with various diameters and thicknesses by incremental forming. J Mech Sci Technol 28:3273–3278.  https://doi.org/10.1007/s12206-014-0738-6 CrossRefGoogle Scholar
  7. 7.
    Raju C, Haloi N, Sathiya Narayanan C (2017) Strain distribution and failure mode in single point incremental forming (SPIF) of multiple commercially pure aluminum sheets. J Manuf Process 30:328–335.  https://doi.org/10.1016/j.jmapro.2017.09.033 CrossRefGoogle Scholar
  8. 8.
    Al-Ghamdi KA, Hussain G (2014) Forming forces in incremental forming of a geometry with corner feature: investigation into the effect of forming parameters using response surface approach. Int J Adv Manuf Technol 76:2185–2197.  https://doi.org/10.1007/s00170-014-6409-z CrossRefGoogle Scholar
  9. 9.
    Li Y, Liu Z, Lu H et al (2014) Efficient force prediction for incremental sheet forming and experimental validation. Int J Adv Manuf Technol 73:571–587.  https://doi.org/10.1007/s00170-014-5665-2 CrossRefGoogle Scholar
  10. 10.
    Emmens WC, van den Boogaard AH (2009) Incremental forming by continuous bending under tension—an experimental investigation. J Mater Process Technol 209:5456–5463.  https://doi.org/10.1016/j.jmatprotec.2009.04.023 CrossRefGoogle Scholar
  11. 11.
    Singh A, Agrawal A (2016) Comparison of deforming forces, residual stresses and geometrical accuracy of deformation machining with conventional bending and forming. J Mater Process Technol 234:259–271.  https://doi.org/10.1016/j.jmatprotec.2016.03.032 CrossRefGoogle Scholar
  12. 12.
    Li Y, Daniel WJT, Liu Z et al (2015) Deformation mechanics and efficient force prediction in single point incremental forming. J Mater Process Technol 221:100–111CrossRefGoogle Scholar
  13. 13.
    Li Y, Daniel WJT, Meehan PA (2016) Deformation analysis in single-point incremental forming through finite element simulation. Int J Adv Manuf Technol.  https://doi.org/10.1007/s00170-016-8727-9 CrossRefGoogle Scholar
  14. 14.
    Saidi B, Boulila A, Ayadi M, Nasri R (2015) Experimental force measurements in single point incremental sheet forming SPIF. Mech Ind 16:410.  https://doi.org/10.1051/meca/2015018 CrossRefGoogle Scholar
  15. 15.
    Aerens R, Eyckens P, Van Bael A, Duflou JR (2010) Force prediction for single point incremental forming deduced from experimental and FEM observations. Int J Adv Manuf Technol 46:969–982.  https://doi.org/10.1007/s00170-009-2160-2 CrossRefGoogle Scholar
  16. 16.
    Aerens R, Duflou JR, Eyckens P, van Bael A (2009) Advances in force modelling for SPIF. Int J Mater Form 2:25–28.  https://doi.org/10.1007/s12289-009-0536-3 CrossRefGoogle Scholar
  17. 17.
    Bagudanch I, Centeno G, Vallellano C, Garcia-Romeu ML (2013) Forming force in single point incremental forming under different bending conditions. Procedia Eng 63:354–360.  https://doi.org/10.1016/j.proeng.2013.08.207 CrossRefGoogle Scholar
  18. 18.
    Mirnia MJ, Dariani BM (2012) Analysis of incremental sheet metal forming using the upper-bound approach. Proc Inst Mech Eng Part B J Eng Manuf 226:1309–1320.  https://doi.org/10.1177/0954405412445113 CrossRefGoogle Scholar
  19. 19.
    Neto DM, Martins JMP, Oliveira MC et al (2016) Evaluation of strain and stress states in the single point incremental forming process. Int J Adv Manuf Technol 85:521–534.  https://doi.org/10.1007/s00170-015-7954-9 CrossRefGoogle Scholar
  20. 20.
    Silva MB, Skjoedt M, Bay N, Martins PAF (2009) Revisiting single-point incremental forming and formability/failure diagrams by means of finite elements and experimentation. J Strain Anal Eng Des 44:221–234.  https://doi.org/10.1243/03093247JSA522 CrossRefGoogle Scholar
  21. 21.
    Li Y, Chen X, Liu Z et al (2017) A review on the recent development of incremental sheet-forming process. Int J Adv Manuf Technol.  https://doi.org/10.1007/s00170-017-0251-z CrossRefGoogle Scholar
  22. 22.
    Li Y, Liu Z, Daniel WJT, Meehan PA (2014) Simulation and experimental observations of effect of different contact interfaces on the incremental sheet forming process. Mater Manuf Process 29:121–128.  https://doi.org/10.1080/10426914.2013.822977 CrossRefGoogle Scholar
  23. 23.
    He S, Gu J, Sol H et al (2007) Determination of strain in incremental sheet forming process. Key Eng Mater 344:503–510.  https://doi.org/10.4028/www.scientific.net/KEM.344.503 CrossRefGoogle Scholar
  24. 24.
    Flores P, Duchêne L, Bouffioux C et al (2007) Model identification and FE simulations: effect of different yield loci and hardening laws in sheet forming. Int J Plast 23:420–449.  https://doi.org/10.1016/j.ijplas.2006.05.006 CrossRefzbMATHGoogle Scholar
  25. 25.
    Ji YH, Park JJ (2008) Formability of magnesium AZ31 sheet in the incremental forming at warm temperature. J Mater Process Technol 201:354–358.  https://doi.org/10.1016/j.jmatprotec.2007.11.206 CrossRefGoogle Scholar
  26. 26.
    Bambach M (2010) A geometrical model of the kinematics of incremental sheet forming for the prediction of membrane strains and sheet thickness. J Mater Process Technol 210:1562–1573.  https://doi.org/10.1016/j.jmatprotec.2010.05.003 CrossRefGoogle Scholar
  27. 27.
    Fatemi A, Dariani BM (2016) The effect of normal and through thickness shear stresses on the formability of isotropic sheet metals. J Braz Soc Mech Sci Eng 38:119–131.  https://doi.org/10.1007/s40430-015-0424-3 CrossRefGoogle Scholar
  28. 28.
    Wojciechowski S (2015) The estimation of cutting forces and specific force coefficients during finishing ball end milling of inclined surfaces. Int J Mach Tools Manuf 89:110–123.  https://doi.org/10.1016/j.ijmachtools.2014.10.006 CrossRefGoogle Scholar
  29. 29.
    Fard MJB, Bordatchev EV (2013) Experimental study of the effect of tool orientation in five-axis micro-milling of brass using ball-end mills. Int J Adv Manuf Technol 67:1079–1089.  https://doi.org/10.1007/s00170-012-4549-6 CrossRefGoogle Scholar
  30. 30.
    Fang Y, Lu B, Chen J et al (2014) Analytical and experimental investigations on deformation mechanism and fracture behavior in single point incremental forming. J Mater Process Technol 214:1503–1515.  https://doi.org/10.1016/j.jmatprotec.2014.02.019 CrossRefGoogle Scholar
  31. 31.
    Bansal A, Lingam R, Yadav SK, Reddy NV (2017) Prediction of forming forces in single point incremental forming. J Manuf Process 1:1.  https://doi.org/10.1016/j.jmapro.2017.04.016 CrossRefGoogle Scholar
  32. 32.
    Lu B, Fang Y, Xu DK et al (2014) Mechanism investigation of friction-related effects in single point incremental forming using a developed oblique roller-ball tool. Int J Mach Tools Manuf 85:14–29.  https://doi.org/10.1016/j.ijmachtools.2014.04.007 CrossRefGoogle Scholar
  33. 33.
    Jackson KP, Allwood JM, Landert M (2008) Incremental forming of sandwich panels. J Mater Process Technol 204:290–303.  https://doi.org/10.1016/j.jmatprotec.2007.11.117 CrossRefGoogle Scholar
  34. 34.
    Ai S, Lu B, Chen J et al (2017) Evaluation of deformation stability and fracture mechanism in incremental sheet forming. Int J Mech Sci 124–125:174–184.  https://doi.org/10.1016/j.ijmecsci.2017.03.012 CrossRefGoogle Scholar
  35. 35.
    Mulay A, Ben S, Ismail S, Kocanda A (2017) Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments. J Braz Soc Mech Sci Eng 39:3997–4010.  https://doi.org/10.1007/s40430-016-0703-7 CrossRefGoogle Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringBirla Institute of Technology and Science PilaniHyderabadIndia

Personalised recommendations