Abstract
Double-sided incremental forming (DSIF) is capable of forming complex three-dimensional components without using component-specific tooling. Forming the components with favourable residual stresses, mechanical properties, and accuracy is still one of the challenging tasks. It is known that the support tool contact condition in DSIF changes the magnitude of residual stresses, thereby allowing the possibility to alter the spring-back and mechanical properties by controlling the support force. In the present work, finite element analysis (FEA) and experimental work are carried out to study the effect of support force (varied from 0 to 500 N) on residual stresses, sheet thinning, and accuracy. A custom-designed tool is used to apply specified force within an acceptable range. In addition, tensile and strain-controlled fatigue tests are also carried out to study the effect of the support force. Results indicate that forming forces predicted using FEA are in good agreement with measured forces. Residual stress measurements and predictions at selected locations indicate that through-thickness residual stress gradients are minimum at a nominal support force (150 N), and improvement in fatigue life is also achieved at the same supporting force.
Similar content being viewed by others
Availability of data and material
Not applicable.
Code availability
Not applicable.
References
Altan T, Tekkaya AE (2012) Sheet metal forming: processes and applications. Published by ASM international
Paralikas J, Salonitis K, Chryssolouris G (2010) Optimization of roll forming process parameters – a semi-empirical approach. Int J Adv Manuf Technol 47(9):1041–1052. https://doi.org/10.1007/s00170-009-2252-z
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 54:88–114. https://doi.org/10.1016/s0007-8506(07)60021-3
Lingam R, Prakash O, Belk JH, Reddy NV (2017) Automatic feature recognition and tool path strategies for enhancing accuracy in double sided incremental forming. Int J Adv Manuf Technol 88(5–8):1639–1655. https://doi.org/10.1007/s00170-016-8880-1
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. ASME J Manuf Sci Eng 133(6):061019(1–10). https://doi.org/10.1115/1.4005179
Meier H, Magnus C, Smukal V (2011) Impact of superimposed pressure on dieless incremental sheet metal forming with two moving tools. CIRP Annals Manuf Technol 60(1):327–330. https://doi.org/10.1016/j.cirp.2011.03.134
Lu B, Fang Y, Xu DK, Chen J, Ai S, Long H, Cao J (2015) Investigation of material deformation mechanism in double side incremental sheet forming. Int J Mach Tools Manuf 93:37–48. https://doi.org/10.1016/j.ijmachtools.2015.03.007
Ren H, Li F, Moser N, Leem D, Li T, Ehmann K, Cao J (2018) General contact force control algorithm in double-sided incremental forming. CIRP Annals Manuf Technol 67(1):381–384. https://doi.org/10.1016/j.cirp.2018.04.057
Konka P, Lingam R, Reddy NV (2020) Tool path design system to enhance accuracy during double sided incremental forming: an analytical model to predict compensations for small/large components. J Manuf process 58:510–523. https://doi.org/10.1016/j.jmapro.2020.08.014
Ren H, Xie J, Liao S, Leem D, Ehmann K, Cao J (2019) In-situ springback compensation in incremental sheet forming. CIRP Annals Manuf Technol 68(1):317–320. https://doi.org/10.1016/j.cirp.2019.04.042
Konka P, Lingam R, Singh UA, Shivaprasad CH, Reddy NV (2020) Enhancement of accuracy in double sided incremental forming by compensating tool path for machine tool errors. Int J Adv Manuf Technol 111(3–4):1187–1199. https://doi.org/10.1007/s00170-020-06149-1
Tanaka S, Nakamura T, Hayakawa K, Nakamura H, Motomura K (2007) Residual stress in sheet metal parts made by incremental forming process. AIP Conf Proc 908(1):775–780. https://doi.org/10.1063/1.2740904
Adabala S, Lingam R, Hayakawa K, Tanaka S, Reddy NV (2019) Experimental and numerical investigation of residual stresses in incremental forming Mater Trans 61(2):228–233. https://doi.org/10.2320/matertrans.MT-ML2019011
Peng W, Li M, Lu B, Chen J, Becker J, Ou H (2019) Experimental and finite element investigation of over-bending phenomenon in double-sided incremental forming (DSIF) of aluminium sheets. Procedia Manuf 29:59–66. https://doi.org/10.1016/j.promfg.2019.02.106
Anyfantis K, Stavropoulos P, Foteinopoulos P, Chryssolouris G (2019) An approach for the design of multi-material mechanical components. Proc Inst Mech Eng B J Eng Manuf 233(3):960–974. https://doi.org/10.1177/0954405418763995
Radu C, Tampu C, Cristea I, Chirita B (2013) The effect of residual stresses on the accuracy of parts processed by SPIF. Mater Manuf Process 28(5):572–576. https://doi.org/10.1080/10426914.2013.763967
Neto DM, Martins JMP, Oliveira MC, Menezes LF, Alves JL (2016) Evolution of strain and stress states in the single point incremental forming process. Int J Adv Manuf Technol 85:521–534. https://doi.org/10.1007/s00170-015-7954-9
Singh A, Agrawal A (2015) Investigation of surface residual stress distribution in deformation machining process for aluminium alloy. J Mater Process Technol 225:195–202. https://doi.org/10.1016/j.jmatprotec.2015.05.025
Jimenez I, Lopez C, Martinez-Romero O, Mares P, Siller H, Diabb J, Sandoval-Robles JA, Elıas-Zuniga A (2017) Investigation of residual stress distribution in single point incremental forming of aluminum parts by x-ray diffraction technique. Int J Adv Manuf Technol 91(5–8):2571–2580. https://doi.org/10.1007/s00170-016-9952-y
Nirala HK, Agrawal A (2020) Residual stress inclusion in the incrementally formed geometry using Fractal Geometry Based Incremental Toolpath (FGBIT). J Mater Process Technol 279:1165–1175. https://doi.org/10.1016/j.jmatprotec.2019.116575
Xu R, Shi X, Xu D, Malhotra R, Cao J (2014) A preliminary study on the fatigue behavior of sheet metal parts formed with accumulative-double-sided incremental forming. Manuf Lett 2(1):8–11. https://doi.org/10.1016/j.mfglet.2013.10.009
Konka P, Reddy NV, Om Prakash, Sahu M (2021) Tool for enhanced accuracy in double sided incremental forming. Patent No. US20210237140A1, 5 August 2021
ASTM International (2010) ASTM E8/E8M standard test methods for tension testing of metallic materials. Annual Book of ASTM Standards 1–24. https://doi.org/10.1520/E0008-04
ASTM International (2012) E606/E606M—12: Standard test method for strain-controlled fatigue testing. 1–16. https://doi.org/10.1520/E0606_E0606M-12
Bansal A, Lingam R, Yadav SK, Reddy NV (2017) Prediction of forming forces in single point incremental forming. J Manuf Process 28(3):486–493. https://doi.org/10.1016/j.jmapro.2017.04.016
Shang HX, Ding HJ (1996) Low cycle fatigue stress-strain relation model of cyclic hardening or cyclic softening materials Eng. Fract Mech 54(1):1–9. https://doi.org/10.1016/0013-7944(95)00144-1
Funding
This work is supported by the Science and Engineering Research Board (SERB), Department of Science and Technology (DST), New Delhi, India (Sanction no. EMR/2015/000286).
Author information
Authors and Affiliations
Contributions
Praveen Konka: Conceptualization, data curation, methodology, validation, investigation, writing original draft, project administration. Shivaprasad Cherukupally: Conceptualization, methodology, investigation, writing—review and editing. N Venkata Reddy: Supervision, resources, writing—review and editing, investigation, funding acquisition.
Corresponding author
Ethics declarations
Ethics approval
Not applicable.
Consent to participate
Not applicable.
Consent for publication
Not applicable.
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Praveen K, CH, S. & Venkata Reddy N Effect of support force on quality during double-sided incremental forming: an experimental and numerical study. Int J Adv Manuf Technol 122, 4275–4292 (2022). https://doi.org/10.1007/s00170-022-09871-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-09871-0