Advertisement

Electric hot incremental sheet forming of Ti-6Al-4V titanium, AA6061 aluminum, and DC01 steel sheets

  • Mostafa Vahdani
  • Mohammad Javad MirniaEmail author
  • Mohammad Bakhshi-Jooybari
  • Hamid Gorji
ORIGINAL ARTICLE
  • 10 Downloads

Abstract

Single point incremental forming (SPIF) is an emerging forming process for rapid prototyping and manufacturing of complex components from sheet metals. Recently, the use of electric current for the local resistance heating of the deformation area has attracted much attention in SPIF. In order to further study the electric hot incremental sheet forming (EHISF), in the present research, the effect of utilizing various lubricants on the formability of Ti-6Al-4V, AA6061, and DC01 sheet metals is experimentally investigated by forming a truncated cone under different feed rates, vertical pitches, and electric currents. To this end, the Taguchi design of experiment (DOE) and the analysis of variance (ANOVA) are employed. The results showed that the formability of Ti-6Al-4V and AA6061 sheets can be improved using the EHISF. For both the sheets, the lubricant and the electric current have significant effects on the maximum achievable forming depth. In addition, the formability of the DC01 sheet is highly affected by the lubricant and the feed rate. The results of the DC01 sheet showed that at the considered wall angle, the maximum forming depth in the EHISF does not change, compared to the cold SPIF, but the thickness distribution of the formed part at a higher temperature is more uniform.

Keywords

Incremental sheet forming (ISF) Hot forming Electrically assisted manufacturing Lubrication condition Formability 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Compliance with ethical standards

Conflict of interest

The authors declare that they have no conflict of interest.

References

  1. 1.
    Shamsari M, Mirnia MJ, Elyasi M, Baseri H (2018) Formability improvement in single point incremental forming of truncated cone using a two-stage hybrid deformation strategy. Int J Adv Manuf Technol 94(5):2357–2368.  https://doi.org/10.1007/s00170-017-1031-5 CrossRefGoogle Scholar
  2. 2.
    Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2007) Laser assisted incremental forming: formability and accuracy improvement. CIRP Ann 56(1):273–276.  https://doi.org/10.1016/j.cirp.2007.05.063 CrossRefGoogle Scholar
  3. 3.
    Fan G, Gao L, Hussain G, Wu Z (2008) Electric hot incremental forming: a novel technique. Int J Mach Tools Manuf 48(15):1688–1692.  https://doi.org/10.1016/j.ijmachtools.2008.07.010 CrossRefGoogle Scholar
  4. 4.
    Xu D, Lu B, Cao T, Chen J, Long H, Cao J (2014) A comparative study on process potentials for frictional stir- and electric hot-assisted incremental sheet forming. Procedia Engineering 81:2324–2329.  https://doi.org/10.1016/j.proeng.2014.10.328 CrossRefGoogle Scholar
  5. 5.
    Al-Obaidi A, Kräusel V, Landgrebe D (2016) Hot single-point incremental forming assisted by induction heating. Int J Adv Manuf Technol 82(5):1163–1171.  https://doi.org/10.1007/s00170-015-7439-x CrossRefGoogle Scholar
  6. 6.
    Ambrogio G, Filice L, Manco GL (2008) Warm incremental forming of magnesium alloy AZ31. CIRP Ann 57(1):257–260.  https://doi.org/10.1016/j.cirp.2008.03.066 CrossRefGoogle Scholar
  7. 7.
    Palumbo G, Brandizzi M (2012) Experimental investigations on the single point incremental forming of a titanium alloy component combining static heating with high tool rotation speed. Mater Des 40:43–51.  https://doi.org/10.1016/j.matdes.2012.03.031 CrossRefGoogle Scholar
  8. 8.
    Mirnia MJ, Dariani BM (2012) Analysis of incremental sheet metal forming using the upper-bound approach. Proc Inst Mech Eng B J Eng Manuf 226(8):1309–1320.  https://doi.org/10.1177/0954405412445113 CrossRefGoogle Scholar
  9. 9.
    Min J, Seim P, Störkle D, Thyssen L, Kuhlenkötter B (2017) Thermal modeling in electricity assisted incremental sheet forming. Int J Mater Form 10(5):729–739.  https://doi.org/10.1007/s12289-016-1315-6 CrossRefGoogle Scholar
  10. 10.
    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 Technol 49(9):941–947.  https://doi.org/10.1007/s00170-009-2472-2 CrossRefGoogle Scholar
  11. 11.
    Ambrogio G, Filice L, Gagliardi F (2012) Formability of lightweight alloys by hot incremental sheet forming. Mater Des 34:501–508.  https://doi.org/10.1016/j.matdes.2011.08.024 CrossRefGoogle Scholar
  12. 12.
    Shi X, Gao L, Khalatbari H, Xu Y, Wang H, Jin L (2013) Electric hot incremental forming of low carbon steel sheet: accuracy improvement. Int J Adv Manuf Technol 68(1):241–247.  https://doi.org/10.1007/s00170-013-4724-4 CrossRefGoogle Scholar
  13. 13.
    Xu DK, Lu B, Cao TT, Zhang H, Chen J, Long H, Cao J (2016) Enhancement of process capabilities in electrically-assisted double sided incremental forming. Mater Des 92:268–280.  https://doi.org/10.1016/j.matdes.2015.12.009 CrossRefGoogle Scholar
  14. 14.
    Honarpisheh M, Abdolhoseini MJ, Amini S (2016) Experimental and numerical investigation of the hot incremental forming of Ti-6Al-4V sheet using electrical current. Int J Adv Manuf Technol 83(9):2027–2037.  https://doi.org/10.1007/s00170-015-7717-7 CrossRefGoogle Scholar
  15. 15.
    Najafabady SA, Ghaei A (2016) An experimental study on dimensional accuracy, surface quality, and hardness of Ti-6Al-4 V titanium alloy sheet in hot incremental forming. Int J Adv Manuf Technol 87(9):3579–3588.  https://doi.org/10.1007/s00170-016-8712-3 CrossRefGoogle Scholar
  16. 16.
    Liu R, Lu B, Xu D, Chen J, Chen F, Ou H, Long H (2016) Development of novel tools for electricity-assisted incremental sheet forming of titanium alloy. Int J Adv Manuf Technol 85(5):1137–1144.  https://doi.org/10.1007/s00170-015-8011-4 CrossRefGoogle Scholar
  17. 17.
    Magnus CS (2017) Joule heating of the forming zone in incremental sheet metal forming: part 1. Int J Adv Manuf Technol 91(1):1309–1319.  https://doi.org/10.1007/s00170-016-9786-7 CrossRefGoogle Scholar
  18. 18.
    Pacheco PAP, Silveira ME (2018) Numerical simulation of electric hot incremental sheet forming of 1050 aluminum with and without preheating. Int J Adv Manuf Technol 94(9):3097–3108.  https://doi.org/10.1007/s00170-017-0879-8 CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Mechanical Engineering DepartmentBabol Noshirvani University of TechnologyBabolIran

Personalised recommendations