Skip to main content
Top

Hint

Swipe to navigate through the articles of this issue

Published in: International Journal of Material Forming 1/2018

21-12-2016 | Original Research

Capability of iterative learning control and influence of the material properties on the improvement of the geometrical accuracy in incremental sheet forming process

Authors: A. Fiorentino, G.C. Feriti, E. Ceretti, C. Giardini

Published in: International Journal of Material Forming | Issue 1/2018

Login to get access
share
SHARE

Abstract

Incremental Sheet Forming (ISF) is a flexible technology that allows the deformation of blank sheets without the need of complex and high cost tools or equipments. One of the main lacks of ISF is the geometrical accuracy which is not comparable with the one achieved by using traditional sheet stamping processes. There are several approaches proposed to enhance this aspect and among them the Authors have developed a method based on an Iterative Learning Control (ILC). ILC consists of a cyclic and progressive error compensation method that improves the quality of the manufactured parts. ILC has been proved to be capable for optimising the production of parts with tight tolerances when dealing with ductile materials (aluminium and steel alloys) and small deformations. In this paper, the method was tested to investigate its capability in a virtual environment. The suggested compensations were checked with Finite Element Method (FEM) so to reduce the number of parts to be manufactured saving time and costs. Moreover, the algorithm was tested considering both a difficult to form material (titanium alloy) and high deformation conditions. The results demonstrated how the precision of ISF processes depends on the blank material properties. Moreover, the capabilities of ILC are shown and discussed.
Literature
1.
go back to reference Leszak E (1967) Apparatus and Process for Incremental Dieless Forming, US. Patent US3342051A1, Published September 19 1967. Leszak E (1967) Apparatus and Process for Incremental Dieless Forming, US. Patent US3342051A1, Published September 19 1967.
3.
go back to reference Nimbalkar DH, Nandedkar VM (2013) Review of incremental forming of sheet metal components. Int J of engineering. Res Appl 3(5):39–51 Nimbalkar DH, Nandedkar VM (2013) Review of incremental forming of sheet metal components. Int J of engineering. Res Appl 3(5):39–51
6.
go back to reference Fiorentino A, Marzi R, Ceretti E (2012) Preliminary results on Ti incremental sheet forming (ISF) of biomedical devices: biocompatibility, surface finishing and treatment. Int J of Mechatronics and Manuf System 5(1):36–45. doi: 10.​1504/​IJMMS.​2012.​046146 CrossRef Fiorentino A, Marzi R, Ceretti E (2012) Preliminary results on Ti incremental sheet forming (ISF) of biomedical devices: biocompatibility, surface finishing and treatment. Int J of Mechatronics and Manuf System 5(1):36–45. doi: 10.​1504/​IJMMS.​2012.​046146 CrossRef
9.
go back to reference Filice L, Fratini L, Micari F (2002) Analysis of material formability in incremental forming. Annals of the CIRP 51(1):199–202 CrossRef Filice L, Fratini L, Micari F (2002) Analysis of material formability in incremental forming. Annals of the CIRP 51(1):199–202 CrossRef
12.
go back to reference Fiorentino A, Marenda GP, Marzi R, Ceretti E, Kemmoku DT, Lopes Da Silva JV (2012) Rapid prototyping techniques for individualized medical prosthesis manufacturing. In: Bartolo P et al (eds) Innovative developments in virtual and physical prototyping - proceedings of the 5th international conference on advanced research and rapid prototyping. CRC Press, London, pp. 589–594 Fiorentino A, Marenda GP, Marzi R, Ceretti E, Kemmoku DT, Lopes Da Silva JV (2012) Rapid prototyping techniques for individualized medical prosthesis manufacturing. In: Bartolo P et al (eds) Innovative developments in virtual and physical prototyping - proceedings of the 5th international conference on advanced research and rapid prototyping. CRC Press, London, pp. 589–594
13.
go back to reference Hussain G, Mahna A, Iqbal A (2016) Response surface analysis of cold formability of polymers in incremental sheet forming: effect of parameters and associated thermal softening. Int J Of Precision Engineering and Manufacturing 17(5):613–621. doi: 10.​1007/​s12541-016-0074-0 CrossRef Hussain G, Mahna A, Iqbal A (2016) Response surface analysis of cold formability of polymers in incremental sheet forming: effect of parameters and associated thermal softening. Int J Of Precision Engineering and Manufacturing 17(5):613–621. doi: 10.​1007/​s12541-016-0074-0 CrossRef
14.
go back to reference Duflou JR, Lauwers B, Verbert J (2007) Study on the achievable accuracy in single point incremental forming. In: Banabic D (ed) Advanced methods in material forming. Springer, Berlin Heidelberg, pp. 251–262 ISBN: 978-3-540-69844-9 CrossRef Duflou JR, Lauwers B, Verbert J (2007) Study on the achievable accuracy in single point incremental forming. In: Banabic D (ed) Advanced methods in material forming. Springer, Berlin Heidelberg, pp. 251–262 ISBN: 978-3-540-69844-9 CrossRef
15.
go back to reference Fiorentino A, Attanasio A, Marzi R, Ceretti E, Giardini C (2011) On forces, formability and geometrical error in metal incremental sheet forming. Int J Mater Prod Technol 40(3–4):277–295. doi: 10.​1504/​IJMPT.​2011 CrossRef Fiorentino A, Attanasio A, Marzi R, Ceretti E, Giardini C (2011) On forces, formability and geometrical error in metal incremental sheet forming. Int J Mater Prod Technol 40(3–4):277–295. doi: 10.​1504/​IJMPT.​2011 CrossRef
18.
go back to reference Duflou JR, Lauwers B, Verbert J, Tunckol Y, De Baerdemaeker H (2005) Achievable accuracy in single point incremental forming: case studies. In: Banabic D (ed) Proceedings of 8th ESAFORM conference on material forming. Publishing House of the Romanian Academy, Cluj-Napoca, pp. 675–678 ISBN 973-27-1173-6 Duflou JR, Lauwers B, Verbert J, Tunckol Y, De Baerdemaeker H (2005) Achievable accuracy in single point incremental forming: case studies. In: Banabic D (ed) Proceedings of 8th ESAFORM conference on material forming. Publishing House of the Romanian Academy, Cluj-Napoca, pp. 675–678 ISBN 973-27-1173-6
30.
go back to reference Rauch M, Hascoet JY, Hamann JC, Plenel Y (2009) Tool path programming optimization for incremental sheet forming applications. Comput Aided Des 41:877–885 CrossRef Rauch M, Hascoet JY, Hamann JC, Plenel Y (2009) Tool path programming optimization for incremental sheet forming applications. Comput Aided Des 41:877–885 CrossRef
31.
go back to reference Allwood JM, Music O, Raithathna A, Duncan SR (2009) Closed-loop feedback control of product properties in flexible metal forming processes with mobile tools. Annals of the CIRP 58:287–290 CrossRef Allwood JM, Music O, Raithathna A, Duncan SR (2009) Closed-loop feedback control of product properties in flexible metal forming processes with mobile tools. Annals of the CIRP 58:287–290 CrossRef
32.
go back to reference Fu Z, Mo J, Han F, Gong P (2013) Tool path correction algorithm for single-point incremental forming of sheet metal. Int J Adv Manuf Technol 64:1239–1248 CrossRef Fu Z, Mo J, Han F, Gong P (2013) Tool path correction algorithm for single-point incremental forming of sheet metal. Int J Adv Manuf Technol 64:1239–1248 CrossRef
36.
go back to reference Moore KL (1993) Iterative learning control for deterministic system. Springer-Verlag, London CrossRefMATH Moore KL (1993) Iterative learning control for deterministic system. Springer-Verlag, London CrossRefMATH
37.
go back to reference ISO 1101:2012. Technical drawings, Geometrical tolerancing, Tolerancing of form, orientation, location and run-out ISO 1101:2012. Technical drawings, Geometrical tolerancing, Tolerancing of form, orientation, location and run-out
39.
go back to reference Attanasio A, Fiorentino A, Mazzoni L, Ceretti E, Giardini C (2008) Design of an Equipment for forces measurement in TPIF process. In: Yang DY (ed) Proceeding of the 9th ICTP. Hanrimweon, Seoul, pp. 1783–1788. doi: 10.​1504/​IJMPT.​2011.​039936 Attanasio A, Fiorentino A, Mazzoni L, Ceretti E, Giardini C (2008) Design of an Equipment for forces measurement in TPIF process. In: Yang DY (ed) Proceeding of the 9th ICTP. Hanrimweon, Seoul, pp. 1783–1788. doi: 10.​1504/​IJMPT.​2011.​039936
40.
go back to reference Garcia-Romeu ML, Pérez-Santiago R, Bagudanch I (2013) Fabrication of a biopsy meso-forceps prototype with incremental sheet forming variants. Int J of mechatronics and. Manuf Syst 6(3):242–253. doi: 10.​1504/​IJMMS.​2013.​056451 Garcia-Romeu ML, Pérez-Santiago R, Bagudanch I (2013) Fabrication of a biopsy meso-forceps prototype with incremental sheet forming variants. Int J of mechatronics and. Manuf Syst 6(3):242–253. doi: 10.​1504/​IJMMS.​2013.​056451
41.
go back to reference Altan T et al (1998) Metal forming handbook / Shuler. Springer-Verlag, New York ISBN 3-540-61185-1 Altan T et al (1998) Metal forming handbook / Shuler. Springer-Verlag, New York ISBN 3-540-61185-1
Metadata
Title
Capability of iterative learning control and influence of the material properties on the improvement of the geometrical accuracy in incremental sheet forming process
Authors
A. Fiorentino
G.C. Feriti
E. Ceretti
C. Giardini
Publication date
21-12-2016
Publisher
Springer Paris
Published in
International Journal of Material Forming / Issue 1/2018
Print ISSN: 1960-6206
Electronic ISSN: 1960-6214
DOI
https://doi.org/10.1007/s12289-016-1335-2

Other articles of this Issue 1/2018

International Journal of Material Forming 1/2018 Go to the issue

Premium Partners