Determination of Failure in Single Point Incremental Forming using Generalized Forming Limit Diagram

Document Type : Manufacturing and Production

Authors

1 Ph.D. Student, Faculty of Mechanical Engineering, University of Guilan, Rasht, Iran

2 Corresponding author: Associate Professor, Faculty of Mechanical Engineering, University of Guilan, Rasht, Iran

3 Assistant Professor, Department of Mechanical Engineering, Takestan Branch, Islamic Azad University, Takestan, Iran

Abstract

Regarding to the uprising need for production of new components with high efficiency, application of methods that could facilitate the prototyping and minimize the financial and time costs are of high importance. Single Point Incremental Forming, which is a process with no need for die manufacturing, was successful in minimizing the costs and the prototyping period required for design validations. Accordingly, studying this process from different perspectives and obtaining an accurate method for determination of failure in this procedure is important. Some of the benefits of this process are an increase in formability, high flexibility in production of complex shapes and reduction of forming forces. In all available processes that are used for forming of metallic sheets there is a certain limit for formality beyond which typical failures including wrinkle, necking or rupture will occur. Today different experimental and numerical methods are developed for determination of forming limit. In this study in order to obtain the forming limits and to anticipate the failure in Single-Point-Incremental-Forming process, generalized forming limit diagrams are utilized. Initially the Single Point Incremental Forming process is simulated using ABAQUS Software and then resulting strain path of critical elements of the part are compared against the forming limits obtained by generalized forming limit diagrams to study the existence of failure in both simulations and experimental tests.

Highlights

  • Obtaining the Generalized forming limit diagram
  • Investigation of the effect of wall angle on maximum attainable forming depth
  • Presenting a new method to failure prediction in the SPIF process

Keywords

References

[1]  Leszak E. Apparatus and process for incremental dieless forming. 1967. Patent US3342051A1.
[2]  Jeswiet J. Incremental single point forming. Trans NAMRI/SME. 2001;29:75-9. DOI :10.1115/IMECE2000-1847.
[3] Filice L, Fratini L, Micari F. Analysis of material formability in incremental forming. CIRP Annals. 2002;51(1):199-202. DOI :10.1016/S0007-8506(07)61499-1.
[4] Keeler SP. Forming limit criteria—sheets. InAdvances in deformation processing 1978 (pp. 127-157). Boston, MA: Springer US.
[5] Keeler SP. Circular grid system—a valuable aid for evaluating sheet metal formability. Sae Transactions. 1968:371-9.
[6] Goodwin GM. Application of strain analysis to sheet metal forming problems in the press shop. Sae Transactions. 1968:380-7.
[7] Hill RT. On discontinuous plastic states, with special reference to localized necking in thin sheets. Journal of the Mechanics and Physics of Solids. 1952;1(1):19-30. DOI :10.1016/0022-5096(52)90003-3.
[8] Marciniak Z, Kuczynski K. Limit strains in the processes of stretch forming sheet steel. Journal of the Mechanics and Physics Solids. 1967:1609-620. DOI :10.1016/0020-7403(67)90066-5.
[9] Sowerby R, Duncan J. Failure in sheet metal in biaxial tension. International Journal of Mechanical Sciences. 1971;13(3):217-29. DOI :10.1016/0020-7403(71)90004-X.
[10] Fatemi A, Dariani BM. The effect of normal and through thickness shear stresses on the formability of isotropic sheet metals. Journal of the Brazilian Society of Mechanical Sciences and Engineering. 2016;38:119-31. DOI :10.1007/s40430-015-0424-3.
[11] Silva MB, Nielsen PS, Bay N, Martins PAF. Failure mechanisms in single-point incremental forming of metals. The International Journal of Advanced Manufacturing Technology. 2011;56(9):893-903. DOI :10.1007/s00170-011-3254-1.
[12]  Su C, Lv S, Wang R, Lv Y, Lou S, Wang Q, Guo S. Effects of forming parameters on the forming limit of single-point incremental forming of sheet metal. The International Journal of Advanced Manufacturing Technology. 2021;113:483-501. DOI :10.1007/s00170-020-06576-0.
[13] Movahedinia H, Mirnia MJ, Elyasi M, Baseri H. An investigation on flaring process of thin-walled tubes using multistage single point incremental forming. The International Journal of Advanced Manufacturing Technology. 2018;94(1):867-80. DOI :10.1007/s00170-017-0971-0.
[14] Shamsari M, Mirnia MJ, Elyasi M, Baseri H. Formability improvement in single point incremental forming of truncated cone using a two-stage hybrid deformation strategy. The International Journal of Advanced Manufacturing Technology. 2018;94(5):2357 -68. DOI :10.1007/s00170-017-1031-5.
[15] Ghaferi M, Mirnia MJ, Elyasi M, Jamshidi Aval H. Evaluation of different heat treatment cycles on improving single point incremental forming of AA6061 aluminum alloy. The International Journal of Advanced Manufacturing Technology. 2019;105(1):83-100. DOI :10.1007/s00170-019-04167-2.
[16] Darzi S, Mirnia MJ, Elyasi M. Experimental investigation of elevated temperature single point incremental forming of AA6061 Aluminum sheet. Modares Mechanical Engineering. 2020;20(8):2171-84. DOR :20.1001.1.10275940.1399.20.8.27.2.
[17] Mirnia MJ, Shamsari M. Numerical prediction of failure in single point incremental forming using a phenomenological ductile fracture criterion. Journal of Materials Processing Technology. 2017;244:17-43. DOI 10.1016/j.jmatprotec.2017.01.029.
[18] Allwood JM, Shouler DR. Generalised forming limit diagrams showing increased forming limits with non-planar stress states. International journal of Plasticity. 2009;25(7):1207-30. DOI :10.1016/j.ijplas.2008.11.001.
[19] Sing W, Rao K. Influence of material properties on sheet metal formability limits. Journal of materials processing technology. 1995;48(1-4):35-41. DOI :10.1016/0924-0136(94)01630-J.
 [20] Taherkhani A, Basti A, Narimanzadeh N, Jamali A. Tool frictional stir effect on dimensional accuracy and formability in single point incremental forming at high rotational speeds. Modares Mechanical Engineering. 2017;16(12):665-74. DOR :20.1001.1.10275940.1395.16.12.71.6.
[21] Mohammadi H, Sharififar M, Ataee AA. Numerical and experimental analysis and optimization of process parameters of AA1050 incremental sheet forming. Journal of Computational Applied Mechanics. 2014;45(1):35-45. DOI :10.22059/JCAMECH.2014.52314.
 
Aerospace Mechanics
Volume 20, Issue 2 - Serial Number 76
Serial No. 75, Summer
July 2024
Pages 39-53

Files

History

  • Receive Date: 31 December 2023
  • Revise Date: 20 January 2024
  • Accept Date: 02 April 2024
  • Publish Date: 21 June 2024

Share

How to cite

Statistics