nach oben

International Journal of Material Forming

Erschienen in:

19.11.2020 | Original Research

Manufacture of an aerospace component with hybrid incremental forming methodology

verfasst von: Pranav Gupta, Alexander Szekeres, Jacob Jeswiet

Erschienen in: International Journal of Material Forming | Ausgabe 2/2021

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config

KI-gestützte Suche

Aus

Abstract

Single point incremental forming is a promising sheet metal forming technique for small batch production. However, the technique is unable to manufacture vertical walls without significant thickness variation and geometrical errors. Two-point incremental forming has the capability of manufacturing vertical walls but requires actuators and intricate rig designs. This paper presents a design facilitating vertical wall manufacturing using a die similar to that used for two-point incremental forming but without actuators. The geometry is created in six passes with a toolpath that can be generated on any leading computer-aided manufacturing software. Manufacturing with this technique reduces geometrical errors in critical areas and improves thickness distribution. This research will be of interest to anyone looking to manufacture prototypes with flat-based geometries in a cost-effective manner.

Vorheriger Artikel Advanced disk-forging process in producing heavy defect-free disk using counteracting dies

Nächster Artikel Investigation of an inverse thermal injection mould design methodology in dependence of the part geometry

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Adams D (2013) Improvements on single point incremental forming through electrically assisted forming, contact area prediction and tool development. Ph.D. Thesis, Queen’s University

Adams D, Jeswiet J (2014) Design rules and applications of single-point incremental forming. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 229 (5):754–760. https://doi.org/10.1177/0954405414531426https://doi.org/10.1177/0954405414531426, http://pib.sagepub.com/content/229/5/754.abstractCrossRef

Ambrogio G, Filice L, Manco GL (2008) Warm incremental forming of magnesium alloy AZ31. CIRP Annals - Manuf Technol 57(1):257–260. https://doi.org/10.1016/j.cirp.2008.03.066, http://www.sciencedirect.com/science/article/pii/S0007850608001054CrossRef

Asghari SAA, Shamsi Sarband A, Habibnia M (2017) Optimization of multiple quality characteristics in two-point incremental forming of aluminum 1050 by grey relational analysis. In: Proceedings of the institution of mechanical engineers, Part c: Journal of Mechanical Engineering Science, pp 095440621769365. https://doi.org/10.1177/0954406217693658

Attanasio A, Ceretti E, Fiorentino A, Mazzoni L, Giardini C (2009) Experimental tests to study feasibility and formability in incremental forming process. Key Eng Mater 410-411:391–400. https://doi.org/10.4028/www.scientific.net/KEM.410-411.391CrossRef

Attanasio A, Ceretti E, Giardini C (2006) Optimization of tool path in two points incremental forming. J Mater Process Technol 177 (1-3):409–412. https://doi.org/10.1016/j.jmatprotec.2006.04.047, http://www.sciencedirect.com/science/article/pii/S0924013606004225CrossRef

Attanasio A, Ceretti E, Giardini C, Mazzoni L (2008) Asymmetric two points incremental forming: Improving surface quality and geometric accuracy by tool path optimization. Journal of Materials Processing Technology. https://doi.org/10.1016/j.jmatprotec.2007.05.053

Bagudanch I, Sabater M, Garcia-Romeu ML (2017) Single point versus two point incremental forming of thermoplastic materials. Adv Mater Process Technol 3(1):135–144. https://doi.org/10.1080/2374068X.2016.1250245CrossRef

Bambach M (2004) Modeling of optimization strategies in the incremental CNC sheet metal forming process. In: AIP Conference proceedings. https://doi.org/10.1063/1.1766822, vol 712. AIP, pp 1969–1974

10.

Buffa G, Campanella D, Fratini L (2013) On the improvement of material formability in SPIF operation through tool stirring action. Int J Adv Manuf Technol 66(9-12):1343–1351. https://doi.org/10.1007/s00170-012-4412-9CrossRef

11.

Centeno G, Bagudanch I, Morales-Palma D, García-Romeu M, Gonzalez-Perez-Somarriba B, Martinez-Donaire A, Gonzalez-Perez L, Vallellano C (2017) Recent approaches for the manufacturing of polymeric cranial prostheses by incremental sheet forming. Procedia Eng 183:180–187. https://doi.org/10.1016/J.PROENG.2017.04.059, https://www.sciencedirect.com/science/article/pii/S1877705817315643CrossRef

12.

Ceretti E, Giardini C, Attanasio A (2004) Experimental and simulative results in sheet incremental forming on CNC machines. J Mater Process Technol 152(2):176–184. https://doi.org/10.1016/j.jmatprotec.2004.03.024, http://linkinghub.elsevier.com/retrieve/pii/S0924013604004534CrossRef

13.

Choi H, Lee C (2019) A mathematical model to predict thickness distribution and formability of incremental forming combined with stretch forming. Robotics and Computer-Integrated Manufacturing 55:164–172. https://doi.org/10.1016/J.RCIM.2018.07.014CrossRef

14.

Duflou J, Lauwers B, Verbert J (2007) Study on the achievable accuracy in single point incremental forming. In: Advanced methods in material forming. https://doi.org/10.1007/3-540-69845-0_15. Springer, Berlin, pp 251–262

15.

Duflou J, Verbert J, Belkassem B, Gu J, Sol H, Henrard C, Habraken A (2008) Process window enhancement for single point incremental forming through multi-step toolpaths. CIRP Annals - Manuf Technol 57(1):253–256. https://doi.org/10.1016/j.cirp.2008.03.030, http://www.sciencedirect.com/science/article/pii/S0007850608000310CrossRef

16.

Ebrahimzadeh P, Baseri H, Mirnia MJ (2018) Formability of aluminum 5083 friction stir welded blank in two-point incremental forming process. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 232(3):267–280. https://doi.org/10.1177/0954408917692370CrossRef

17.

Emmens WC, Sebastiani G, Van den Boogaard AH (2010) The technology of Incremental Sheet Forming-A brief review of the history. Journal of Materials Processing Technology. https://doi.org/10.1016/j.jmatprotec.2010.02.014

18.

Formisano A, Boccarusso L, Capece Minutolo F, Carrino L, Durante M, Langella A (2017) Negative and positive incremental forming: Comparison by geometrical, experimental, and FEM considerations. Mater Manuf Process 32(5):530–536. https://doi.org/10.1080/10426914.2016.1232810CrossRef

19.

Gupta P, Jeswiet J (2017) Effect of temperatures during forming in single point incremental forming. The International Journal of Advanced Manufacturing Technology, pp 1–14. https://doi.org/10.1007/s00170-017-1400-0

20.

Gupta P, Jeswiet J (2017) Observations on heat generated in single point incremental forming. In: Procedia Engineering. https://doi.org/10.1016/j.proeng.2017.04.060, http://www.sciencedirect.com/science/article/pii/S1877705817315655, vol 183. Elsevier, pp 161–167

21.

Gupta P, Jeswiet J (2019) Manufacture of an aerospace component by single point incremental forming. Procedia Manuf 29:112–119. https://doi.org/10.1016/j.promfg.2019.02.113, https://www.sciencedirect.com/science/article/pii/S2351978919301465, https://linkinghub.elsevier.com/retrieve/pii/S2351978919301465CrossRef

22.

Gupta P, Szekeres A, Jeswiet J (2019) Design and development of an aerospace component with single-point incremental forming. The International Journal of Advanced Manufacturing Technology, pp 1–20. https://doi.org/10.1007/s00170-019-03622-4

23.

Hino R, Kawabata K, Yoshida F (2014) Incremental forming with local heating by laser irradiation for magnesium alloy sheet. In: Procedia Engineering. https://doi.org/10.1016/j.proeng.2014.10.329, http://www.sciencedirect.com/science/article/pii/S1877705814016087, vol 81. Elsevier, pp 2330–2335

24.

Hirt G, Ames J, Bambach M (2005) A new forming strategy to realise parts designed for deep-drawing by incremental CNC sheet forming. Steel Research International. https://doi.org/10.1002/srin.200505989

25.

Hirt G, Ames J, Bambach M, Kopp R (2004) Forming strategies and Process Modelling for CNC Incremental Sheet Forming. CIRP Ann Manuf Technol 53(1):203–206. https://doi.org/10.1016/S0007-8506(07)60679-9CrossRef

26.

Hirt G, Bambach M, Bleck W, Prahl U, Stollenwerk J (2015) The development of incremental sheet forming from flexible forming to fully integrated production of sheet metal parts. In: Brecher C. (ed) Advances in production technology. Springer International Publishing, Cham, pp 117–129

27.

Jackson K, Allwood J (2009) The mechanics of incremental sheet forming. J Mater Process Technol 209(3):1158–1174. https://doi.org/10.1016/j.jmatprotec.2008.03.025, http://linkinghub.elsevier.com/retrieve/pii/S0924013608002422CrossRef

28.

Jeswiet J, Adams D, Doolan M, McAnulty T, Gupta P (2015) Single point and asymmetric incremental forming. Adv Manuf 3(4):253–262. https://doi.org/10.1007/s40436-015-0126-1CrossRef

29.

Jeswiet J, Micari F, Hirt G, Bramley A, Duflou J, Allwood J (2005) Asymmetric single point incremental forming of sheet metal. CIRP Ann Manuf Technol 54(2):88–114CrossRef

30.

Lasunon O, Knight WA (2007) Comparative investigation of single-point and double-point incremental sheet metal forming processes. In: Proceedings of the institution of mechanical engineers part b: journal of engineering manufacture. https://doi.org/10.1243/09544054JEM865

31.

Li JC, Yang FF, Zhou ZQ (2015) Thickness distribution of multi-stage incremental forming with different forming stages and angle intervals. J Cent South Univ 22(3):842–848. https://doi.org/10.1007/s11771-015-2591-xCrossRef

32.

Li X, Han K, Li D (2018) Multi-Stage Two point incremental sheet forming. Journal of Physics: Conference Series 1063(1):012064. https://doi.org/10.1088/1742-6596/1063/1/012064, http://stacks.iop.org/1742-6596/1063/i=1/a=012064?key=crossref.3ecce46ed8f382ef46bb688afea3c4e0

33.

Li X, Han K, Yu H, Zhang Y, Li D (2016) Effect of some process parameters on geometric errors in twopoint incremental forming for Al-Cu-Mg Aluminum Alloy. In: Journal of physics: Conference series. https://doi.org/10.1088/1742-6596/734/3/032078

34.

Liu Z, Meehan P, Bellette P (2011) Thickness distribution and forming strategy analysis for two point Incremental Forming with a male die. Adv Mater Res 337:452–455. https://doi.org/10.4028/www.scientific.net/AMR.337.452CrossRef

35.

Lu B, Chen J, Ou H, Cao J (2013) Feature-based tool path generation approach for incremental sheet forming process. J Mater Process Technol 213(7):1221–1233. https://doi.org/10.1016/j.jmatprotec.2013.01.023, http://www.sciencedirect.com/science/article/pii/S092401361300040XCrossRef

36.

Malhotra R, Bhattacharya A, Kumar A, Reddy N, Cao J (2011) A new methodology for multi-pass single point incremental forming with mixed toolpaths. CIRP Annals - Manuf Technol 60(1):323–326. https://doi.org/10.1016/j.cirp.2011.03.145, http://www.sciencedirect.com/science/article/pii/S0007850611001466CrossRef

37.

Malhotra R, Cao J, Ren F, Kiridena V, Cedric Xia Z, Reddy NV (2011) Improvement of geometric accuracy in incremental forming by using a squeezing Toolpath strategy with two forming tools. J Manuf Sci Eng 133(6):061019. https://doi.org/10.1115/1.4005179. http://manufacturingscience.asmedigitalcollection.asme.org/article.aspx?articleid=1460624CrossRef

38.

Malhotra R, Reddy N, Agrawal A (2007) Automatic path generation for incremental sheet metal forming. In: Verma R, Bhattacharjee D (eds) Proc Symp Automotive Steel. https://books.google.ca/books?id=LvF2pixQN3wC&dq=incremental+sheet+forming&source=gbs_navlinks_s. Tata McGraw-Hill Education, Jamshedpur, pp 97–101

39.

Malhotra R, Reddy NV, Cao J (2010) Automatic 3D spiral Toolpath generation for single point incremental forming. J Manuf Sci Eng 132(6):061003. https://doi.org/10.1115/1.4002544, http://manufacturingscience.asmedigitalcollection.asme.org/article.aspx?articleid=1452475CrossRef

40.

Matsubara S (1994) Incremental backward bulge forming of a sheet metal with a hemispherical tool. Journal of the JSTP

41.

Matsubara S (1995) Method and device for forming metal plate. https://patents.google.com/patent/JPH07132329A/en

42.

Matsubara S (2001) A computer numerically controlled dieless incremental forming of a sheet metal. In: Proceedings of the institution of mechanical engineers, Part B: Journal of Engineering Manufacture. https://doi.org/10.1243/0954405011518863, vol 215. Professional Engineering Publishing, pp 959–966

43.

Micari F, Ambrogio G, Filice L (2007) Shape and dimensional accuracy in Single Point Incremental Forming: State of the art and future trends. J Mater Process Technol 191(1-3):390–395. https://doi.org/10.1016/j.jmatprotec.2007.03.066, http://www.sciencedirect.com/science/article/pii/S0924013607002919CrossRef

44.

Mostafanezhad H, Menghari HG, Esmaeili S, Shirkharkolaee EM (2018) Optimization of two-point incremental forming process of AA1050 through response surface methodology. Measurement 127:21–28. https://doi.org/10.1016/J.MEASUREMENT.2018.04.042, https://www.sciencedirect.com/science/article/pii/S026322411830318X#b0065CrossRef

45.

Otsu M, Yasunaga M, Matsuda M, Takashima K (2014) Friction stir incremental forming of A2017 aluminum sheets. Procedia Engineering 81:2318–2323. https://doi.org/10.1016/j.proeng.2014.10.327, http://www.sciencedirect.com/science/article/pii/S1877705814016063CrossRef

46.

Park J, Kim Y (2003) Fundamental studies on the incremental sheet metal forming technique. J Mater Process Technol 140(1-3):447–453. https://doi.org/10.1016/S0924-0136(03)00768-4CrossRef

47.

Puzik A (2008) Incremental sheet forming with a robot system for an industrial application. In: Manufacturing systems and technologies for the new frontier. https://doi.org/10.1007/978-1-84800-267-8_86. Springer, London, pp 421–424

48.

Shin J, Bansal A, Nath M, Cheng R, Banu M, Taub A, Martinek B (2018) Prediction of negative bulge in two point incremental forming of an asymmetric shape part. Journal of Physics: Conference Series 1063(1):012057. https://doi.org/10.1088/1742-6596/1063/1/012057, http://stacks.iop.org/1742-6596/1063/i=1/a=012057?key=crossref.d9ff4fc5dbbcf53a005118e697dd1d87

49.

Silva MB, Martins PAF (2013) Two-Point Incremental forming with partial die: theory and experimentation. J Mater Eng Perform 22(4):1018–1027. https://doi.org/10.1007/s11665-012-0400-3CrossRef

50.

Skjoedt M, Bay N, Endelt B, Ingarao G (2008) Multi stage strategies for single point incremental forming of a cup. Int J Mater Form 1(S1):1199–1202. https://doi.org/10.1007/s12289-008-0156-3CrossRef

51.

Skjoedt M, Silva MB, Martins PAF, Bay N (2010) Strategies and limits in multi-stage single-point incremental forming. J Strain Anal Eng Design 45(1):33–44. https://doi.org/10.1243/03093247JSA574CrossRef

52.

Verbert J, Belkassem B, Henrard C, Habraken AM, Gu J, Sol H, Lauwers B, Duflou JR (2008) Multi-Step toolpath approach to overcome forming limitations in single point incremental forming. Int J Mater Form 1(S1):1203–1206. https://doi.org/10.1007/s12289-008-0157-2CrossRef

53.

Verbert J, Duflou JR, Lauwers B (2009) Feature based approach for increasing the accuracy of the SPIF process key engineering materials. https://doi.org/10.4028/www.scientific.net/kem.344.527

54.

Ziran X, Gao L, Hussain G, Cui Z (2009) The performance of flat end and hemispherical end tools in single-point incremental forming. Int J Adv Manuf Technol 46 (9-12):1113–1118. https://doi.org/10.1007/s00170-009-2179-4CrossRef

Titel: Manufacture of an aerospace component with hybrid incremental forming methodology
verfasst von: Pranav Gupta
Alexander Szekeres
Jacob Jeswiet
Publikationsdatum: 19.11.2020
Verlag: Springer Paris
Erschienen in: International Journal of Material Forming / Ausgabe 2/2021
Print ISSN: 1960-6206
Elektronische ISSN: 1960-6214
DOI: https://doi.org/10.1007/s12289-020-01601-9

Premium Partner

Marktübersichten

Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.

Zur Marktübersicht

Springer Professional

Abstract

Bitte loggen Sie sich ein, um Zugang zu Ihrer Lizenz zu erhalten.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Weitere Artikel der Ausgabe 2/2021

Calibration of the residual stresses with an active die during the ejection phase of cold extrusion

Influence of surface roughness on cold formability in bending processes: a multiscale modelling approach with the hybrid damage mechanics model

Investigation of an inverse thermal injection mould design methodology in dependence of the part geometry

A study of the mechanical properties of a Mg-Al-Zn alloy (AZ91) produced via Thixomolding

Deformability of bamboo impregnated with thermosetting resin in upset forging

Study and modeling of high-density polyethylene coalescence under the extrussion conditions

Premium Partner

Marktübersichten