Skip to main content
SpringerLink
Log in

Forming forces in incremental forming of a geometry with corner feature: investigation into the effect of forming parameters using response surface approach

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Single-point incremental forming (SPIF) is an emerging sheet forming process. The force-parameter correlation is yet not well clear in this process, specifically for geometries with corners. In the present study, a new level of understanding on the parameter-force relationship is presented. A simple shape with corners (i.e., frustum of pyramid containing corners and oblique wall) is opted as the test geometry. Following the response surface method, a design of experiments (DoE) comprising of 47 runs obtained by varying five forming parameters namely sheet thickness, tool diameter, wall angle, step size, and flow stress is performed. The analysis of the results reveals that the parameter-force relation in SPIF is complex and interactive, explaining that the effect of variation in a parameter on the force magnitude is closely associated with the value and the type of the other parameters employed for forming. From the analysis of the forces involved in forming the pyramid, it is found that the corner requires more force than does the wall. Further, the normal force (i.e., force along normal to sheet plane) is greater than the in-plane force. The use of very small tools, especially low d/t o where d is the tool diameter and t o is the sheet thickness, is observed to cause fabrication defects leading to substantial rise in the magnitude of forming force thus endangering the machine tool. Finally, a set of force models is proposed using which one can predict a set of forming parameters simultaneously minimizing the force and preventing the fabrication problems.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Lim WS, Choi HS, Ahn SY, Kim BM (2014) Cooling channel design of hot stamping tools for uniform high-strength components in hot stamping process. Int J Adv Manuf Tech 70:1189–1203

    Article  Google Scholar 

  2. Hsu TJ (1974) Present scope and future trend of sheet metal forming research. Int J Prod Res 12(1):99–115

    Article  Google Scholar 

  3. Hagan E, Jeswiet J (2003) A review of conventional and modern single-point sheet metal forming methods. P I Mech Eng B-J Eng 217:213–225

    Google Scholar 

  4. Echrif SBM, Hrairi M (2011) Research and progress in incremental sheet forming processes. Mater Manuf Process 26:1404–1414

    Article  Google Scholar 

  5. Li M, Li Z, Mo JH, Lu Y (2012) Tool-path generation for sheet metal incremental forming based on STL model with defects. Int J Adv Manuf Tech 63:535–547

    Article  Google Scholar 

  6. Silva MB, Nielsen PS, Bay N, Martins PAF (2011) Failure mechanisms in single point incremental forming of metals. Int J Adv Manuf Tech 56:893–903

    Article  Google Scholar 

  7. Hussain G, Gao L, Zhang ZY (2008) Formability evaluation of the pure titanium sheet in the cold incremental forming process. Int J Adv Manuf Tech 37:920–926

    Article  Google Scholar 

  8. Ziran X, Gao L, Hussain G, Cui Z (2010) The performance of flat end and hemispherical end tools in single-point incremental forming. Int J Adv Manuf Tech 46:1113–1118

    Article  Google Scholar 

  9. Hussain G, Gao L, Hayat N, Dar NU (2010) The formability of annealed and pre-aged AA-2024 sheets in single-point incremental forming. Int J Adv Manuf Tech 46:543–549

    Article  Google Scholar 

  10. Amino H, Lu Y, Ozawa S, Fakuda K, Maki T (2002) Dieless NC forming of automotive service panels. In: Proceeding of the conference on advanced technology of plasticity, JSTP Japan, p 1015–1020

  11. Ambrogio G, Napoli LD, Filice L, Gagliardi F, Muzzupappa M (2005) Application of incremental forming process for highly customized medical product manufacturing. J Mater Process Tech 162–163:156–162

    Article  Google Scholar 

  12. Ambrogio G, Filice L, Gagliardi F (2012) Improving industrial suitability of incremental sheet forming process. Int J Adv Manuf Tech 58:941–947

    Article  Google Scholar 

  13. Fan G, Sun F, Meng X, Gao L, Tong G (2010) Electric hot incremental forming of Ti-6Al-4V titanium sheet. Int J Adv Manuf Tech 49:941–947

    Article  Google Scholar 

  14. Li J, Bai T, Zhou Z (2014) Numerical simulation and experimental investigation of incremental sheet forming with an elastic support. Int J Adv Manuf Tech. doi:10.1007/s00170-014-6117-8

    Google Scholar 

  15. Iseki H (2001) An approximate deformation analysis and FEM analysis for the incremental bulging of sheet metal using a spherical roller. J Mater Process Tech 11:150–154

    Article  Google Scholar 

  16. Silva MB, Skjoedt M, Martins PAF, Bay N (2008) Revisiting the fundamentals of single point incremental forming by means of membrane analysis. Int J Mach Tool Manu 48:73–83

    Article  Google Scholar 

  17. Bagudanch I, Centeno G, Vallellano C, Garcia ML (2013) Forming forces in single point incremental forming under different bending conditions. In: Proceedings of 5th Manufacturing Engineering Society International Conference, Zaragoza. Pages not available

  18. Ambrogio G, Filice L, Micari F (2006) A force measuring based strategy for failure prevention in incremental forming. J Mater Process Tech 117:413–416

    Article  Google Scholar 

  19. Arfa H, Bahloul R, Bel HSH (2012) Finite element modelling and experimental investigation of single point incremental forming process of aluminum sheets: influence of process parameters on punch force monitoring and on mechanical and geometrical quality of parts. Int J Mater Form. doi:10.1007/s12289-012-1101-z

    Google Scholar 

  20. Henrard C, Bouffioux C, Eyckens P, Sol H, Duflou JR, Van HP, Van-Bael A, Duchêne L, Habraken AM (2011) Forming forces in single point incremental forming: prediction by finite element simulations, validation and sensitivity. Comput Mech 47:573–590

    Article  MATH  Google Scholar 

  21. Duflou JR, Tunçkol Y, Szekeres A, Vanherck P (2007) Experimental study on force measurements for single point incremental forming. J Mater Process Tech 189:65–72

  22. Aerens R, Eyckens P, Van-Bael A, Duflou JR (2009) Force prediction for single point incremental forming deduced from experimental and FEM observations. Int J Adv Manuf Tech. doi:10.1007/s00170-009-2160-2

    Google Scholar 

  23. Hussain G, Gao L, Hayat N (2007) A new parameter and its effect on the formability in single point incremental forming: a fundamental investigation. J Mech Sci Technol 24:1–7

    Google Scholar 

  24. Centeno G, Bagudanch I, Martinez DAJ, Garcia RML, Vallellano C (2014) Critical analysis of necking and fracture limit strains and forming forces in single-point incremental forming. Mater Des 63:20–29

    Article  Google Scholar 

  25. Hussain G, Khan HR, Hayat N (2013) Guidelines for tool size selection for SPIF of an aerospace alloy. Mater Manuf Process 28:324–329

    Article  Google Scholar 

  26. Montgomery DC (1997) Design and analysis of experiments, 4th edn. Wiley, New York

    MATH  Google Scholar 

  27. Al-Ghamdi KA, Hussain G (2014) Threshold tool-radius condition maximizing the formability in SPIF considering a variety of materials: experimental and FE investigations. Int J Mach Tool Manuf (Submitted)

  28. Hussain G, Al-Ghamdi KA, Khalatbari H, Iqbal A, Hashemipoure M (2013) Forming parameters and forming defects in incremental forming: Part B. Mater Manuf Process (Accepted)

  29. Anderson MJ, Whitcomb PJ (2004) RSM simplified: optimizing processes using response surface methods for design of experiments. Taylor & Francis, London

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Industrial Engineering, King Abdulaziz University, Jeddah, Kingdom of Saudi Arabia

    Khalid A. Al-Ghamdi

  2. Mechanical Engineering Department, Eastern Mediterranean University, TRNC, Via Mersin-10, Turkey

    G. Hussain

Authors
  1. Khalid A. Al-Ghamdi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. G. Hussain
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to G. Hussain.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Al-Ghamdi, K.A., Hussain, G. 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 (2015). https://doi.org/10.1007/s00170-014-6409-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-014-6409-z

Keywords

Search

Navigation