Abstract
Single point incremental forming is a flexible sheet forming process that does not require a dedicated punch and die for making products for various applications. However, forming parts at steep wall angles, closer to 90°, using this process poses difficulties due to excessive thinning. The motivation behind this study is to overcome the challenges associated with forming parts at steep wall angles using the single point incremental forming process. Controlling the thickness distribution is a significant challenge that needs to be addressed. Excessive thinning leads to disqualification of design criteria, thereby restricting the process’ industrial applicability. In the present work, an improved clamping mechanism along with a multi-stage forming approach is employed to address the issue of excessive thinning. Two strategies were evolved; in strategy 1, an improved clamping mechanism was developed for single stage single point incremental forming, while strategy 2 consists of the improved clamping strategy along with a multi-stage forming approach for a single point incremental forming process. The improved clamping was based on the deep drawing process’ blank holding type clamping mechanism in both these strategies. The study aimed to compare the formed components’ forming depth and thickness distribution using the two strategies. The result revealed that strategy 2 was more effective, resulting in better thickness distribution in the formed component. The thickness distribution improvement resulted from metal flow from the flange region, owing to the improved clamping strategy, during the single and multi-stage forming at steep wall angles.
Similar content being viewed by others
References
Kotkunde N, Deole AD, Gupta AK et al (2014) Failure and formability studies in warm deep drawing of Ti-6Al-4V alloy. Mater Des 60:540–547. https://doi.org/10.1016/j.matdes.2014.04.040
Bassoli E, Sola A, Denti L, Gatto A (2019) Experimental approach to measure the restraining force in deep drawing by means of a versatile draw bead simulator. Mater Manuf Process 34:1286–1295. https://doi.org/10.1080/10426914.2019.1628267
Dwivedi R, Choubey AK, Purohit R, Rana RS (2021) Experimental and numerical analysis of aluminium alloy cylindrical cup using novel deep drawing technique. Adv Mater Process Technol 00:1–14. https://doi.org/10.1080/2374068X.2021.1878701
Agrawal A, Reddy NV, Dixit PM (2007) Determination of optimum process parameters for wrinkle free products in deep drawing process. J Mater Process Technol 191:51–54. https://doi.org/10.1016/j.jmatprotec.2007.03.050
Agrawal A, Reddy NV, Dixit PM (2008) Optimal blank shape prediction considering sheet thickness variation: an upper bound approach. J Mater Process Technol 196:249–258. https://doi.org/10.1016/j.jmatprotec.2007.05.046
Wan M, Yang YY, Ben LS (2001) Determination of the limiting drawing coefficient in the deep drawing of conical cups. J Mater Process Technol 114:114–117. https://doi.org/10.1016/S0924-0136(01)00729-4
Leu DK, Wu JY (2004) A simplified approach to estimate limiting drawing ratio and maximum drawing load in cup drawing. J Eng Mater Technol 126:116–122. https://doi.org/10.1115/1.1633574
Kotkunde N, Krishna G, Shenoy SK et al (2017) Experimental and theoretical investigation of forming limit diagram for Ti-6Al-4 V alloy at warm condition. Int J Mater Form 10:255–266. https://doi.org/10.1007/s12289-015-1274-3
Khalatbari H, Lazoglu I (2021) Friction stir incremental forming of polyoxymethylene: process outputs, force and temperature. Mater Manuf Process 36:94–105. https://doi.org/10.1080/10426914.2020.1819542
Kumar N, Singh A, Agrawal A (2020) Formability analysis of AA1200 H14 aluminum alloy using single point incremental forming process. Trans Indian Inst Met 73:1975–1984. https://doi.org/10.1007/s12666-020-02014-7
Wankhede P, K M, Kurra S, Singh SK, (2022) Heat treatment and temperature effects on formability of AA2014-T6 in incremental forming. Mater Manuf Process 37:1384–1392. https://doi.org/10.1080/10426914.2021.2016813
Suresh K, Bagade SD, Regalla SP (2015) Deformation behavior of extra deep drawing steel in single-point incremental forming. Mater Manuf Process 30:1202–1209. https://doi.org/10.1080/10426914.2014.994755
Kim YH, Park JJ (2002) Effect of process parameters on formability in incremental forming of sheet metal. J Mater Process Technol 130–131:42–46. https://doi.org/10.1016/S0924-0136(02)00788-4
Malhotra R, Reddy NV, Cao J (2010) Automatic 3D spiral toolpath generation for single point incremental forming. J Manuf Sci Eng 132:1–10. https://doi.org/10.1115/1.4002544
Nirala HK, Jain PK, Roy JJ et al (2017) An approach to eliminate stepped features in multistage incremental sheet forming process: experimental and FEA analysis. J Mech Sci Technol 31:599–604. https://doi.org/10.1007/s12206-017-0112-6
Gandla PK, Pandre S, Suresh K, Kotkunde N (2022) A critical analysis of formability and quality parameters for forming a dome shape using multi-stage strategies in incremental forming process. J Mater Res Technol 19:1037–1048. https://doi.org/10.1016/j.jmrt.2022.05.064
Seyyedi SE, Gorji H, Mirnia MJ, Bakhshi-Jooybari M (2022) Prediction of ductile damage and fracture in the single- and multi-stage incremental hole-flanging processes using a new damage accumulation law. Int J Adv Manuf Technol 119:4757–4780. https://doi.org/10.1007/s00170-021-08638-3
Echrif SBM, Hrairi M (2011) Research and progress in incremental sheet forming processes. Mater Manuf Process 26:1404–1414. https://doi.org/10.1080/10426914.2010.544817
Kim T, Yang D (2000) Improvement of formability for the incremental sheet metal forming process. Int J Mech Sci 42:1271–1286. https://doi.org/10.1016/S0020-7403(99)00047-8
Liu Z, Li Y, Meehan PA (2013) Vertical wall formation and material flow control for incremental sheet forming by revisiting multistage deformation path strategies. Mater Manuf Process 28:562–571. https://doi.org/10.1080/10426914.2013.763964
Duflou JR, Verbert J, Belkassem B et al (2008) Process window enhancement for single point incremental forming through multi-step toolpaths. CIRP Ann - Manuf Technol 57:253–256. https://doi.org/10.1016/j.cirp.2008.03.030
Skjoedt M, Bay N, Endelt B, Ingarao G (2008) Multi stage strategies for single point incremental forming of a cup. Int J Mater Form 1:1199–1202. https://doi.org/10.1007/s12289-008-0156-3
Malhotra R, Bhattacharya A, Kumar A et al (2011) A new methodology for multi-pass single point incremental forming with mixed toolpaths. CIRP Ann - Manuf Technol 60:323–326. https://doi.org/10.1016/j.cirp.2011.03.145
Li J, Shen J, Wang B (2013) A multipass incremental sheet forming strategy of a car taillight bracket. Int J Adv Manuf Technol 69:2229–2236. https://doi.org/10.1007/s00170-013-5179-3
Lingam R, Bansal A, Reddy NV (2016) Analytical prediction of formed geometry in multi-stage single point incremental forming. Int J Mater Form 9:395–404. https://doi.org/10.1007/s12289-015-1226-y
Li X, Han K, Xu P et al (2020) Experimental and theoretical analysis of the thickness distribution in multistage two point incremental sheet forming. Int J Adv Manuf Technol 107:191–203. https://doi.org/10.1007/s00170-020-05037-y
Ghafoor S, Li Y, Zhao G et al (2022) Deformation characteristics and formability enhancement during ultrasonic-assisted multi-stage incremental sheet forming. J Mater Res Technol 18:1038–1054. https://doi.org/10.1016/j.jmrt.2022.03.036
Kumar N, Agrawal A, Belokar RM, Kausshal N (2022) Finite element analysis of heat assisted incremental sheet forming process. Adv Mater Process Technol 00:1–9. https://doi.org/10.1080/2374068x.2022.2117440
Li JC, Li C, Zhou TG (2012) Thickness distribution and mechanical property of sheet metal incremental forming based on numerical simulation. Trans Nonferrous Met Soc China 22:s54–s60. https://doi.org/10.1016/S1003-6326(12)61683-5. (English Ed)
Iqbal MA, Khan SH, Ansari R, Gupta NK (2013) Experimental and numerical studies of double-nosed projectile impact on aluminum plates. Int J Impact Eng 54:232–245. https://doi.org/10.1016/j.ijimpeng.2012.11.007
John J, Shanmuganatan SP, Kiran MB et al (2021) Friction stir processing combined with incremental forming effect on AA2014-T6. Mater Manuf Process 36:950–966. https://doi.org/10.1080/10426914.2021.1885696
Acknowledgements
This work was supported by the Science and Engineering Research Board [CRG/2022/008003] and Aeronautics R&D Board [2076].
Author information
Authors and Affiliations
Contributions
Narinder Kumar: conceptualization of this study, methodology, investigation, experimental and simulation data curation, formal analysis, writing—original draft preparation. Rakesh Lingam: writing—review, editing, and formal analysis. Anupam Agrawal: resources, visualization, methodology, supervision, and project administration.
Corresponding author
Ethics declarations
Competing interests
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 (e.g. a society or other partner) 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
Kumar, N., Lingam, R. & Agrawal, A. Enhancement of incremental forming process formability by using improved clamping and multi-stage deformation strategies. Int J Adv Manuf Technol 129, 659–670 (2023). https://doi.org/10.1007/s00170-023-12298-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-023-12298-w