Skip to main content
SpringerLink
Log in

An assessment of various process strategies for improving precision in single point incremental forming

  • Original Research
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

Single point incremental forming (SPIF) is a process with the capability to form complex geometries using a tool of very simple geometry, without the need for a matching die. However, large elastic springback resulting from the die-less nature of the process can cause problems if high levels of accuracy are required. The aim of this investigation is to use numerical modelling to investigate different strategies to improve the process precision. A finite-element (FE) model has been used to investigate the effects of adding a backing plate, a supporting kinematic tool and modifying the final stage of the tool path. The results show that the backing plate will minimise the sheet bending near to the initial tool contact location; the additional kinematic tool will reduce springback; and the extension of the tool path across the base of the sheet will eliminate the pillow effect. The cumulative effect of introducing these features to the process shows an improvement in the overall accuracy of the profile and in the thickness distributions of the final product. The results contribute to a better understanding of springback in SPIF.

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

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

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

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

References

  1. Dejardin S, Thibaud S, Gelin J (2008) Finite element analysis and experimental investigations for improving precision in single point incremental sheet forming process. Int J Mater Form 1:121–124

    Article  Google Scholar 

  2. Duflou J, Tunçkol Y, Szekeres A, Vanherck P (2007) Experimental study on force measurements for single point incremental forming. J Mater Process Technol 189(1–3):65–72

    Article  Google Scholar 

  3. Micari F, Ambrogio G, Filice L (2007) Shape and dimensional accuracy in Single Point Incremental Forming: state of the art and future trends. J Mater Process Technol 191(1–3):390–395

    Article  Google Scholar 

  4. Lasunon O, Knight W (2007) Comparative investigation of single-point and double-point incremental sheet metal forming processes. Proc Inst Mech Eng B: J Eng Manuf 221(12):1725–1732

    Article  Google Scholar 

  5. 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(2):88–114

    Article  Google Scholar 

  6. Ambrogio G, Filice L, De Napoli L, Muzzupappa M (2005) A simple approach for reducing profile diverting in a single point incremental forming process. Proc Inst Mech Eng B: J Eng Manuf 219(11):823–830

    Article  Google Scholar 

  7. Ambrogio G, Cozza V, Filice L, Micari F (2007) An analytical model for improving precision in single point incremental forming. J Mater Process Technol 191(1–3):92–95

    Article  Google Scholar 

  8. Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2007) Laser assisted incremental forming: formability and accuracy improvement. CIRP Anna - Manuf Technol 56(1):273–276

    Article  Google Scholar 

  9. Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2008) Improved SPIF performance through dynamic local heating. Int J Mach Tools Manuf 48(5):543–549

    Article  Google Scholar 

  10. Attanasio A, Ceretti E, Giardini C (2006) Optimization of tool path in two point incremental forming. J Mater Process Technol 177(1–3):409–412

    Article  Google Scholar 

  11. Attanasio A, Ceretti E, Giardini C, Mazzoni L (2008) Asymmetric two point incremental forming: improving surface quality and geometric accuracy by tool path optimization. J Mater Process Technol 197(1–3):59–67

    Article  Google Scholar 

  12. Franzen V, Kwiatkowski L, Sebastiani G, Shankar R, Tekkaya E, Kleiner M (2008) Dyna-die: towards full kinematic incremental forming. Int J Mater Form 1:1163–1166

    Article  Google Scholar 

  13. Bambach M, Taleb Araghi B, Hirt G (2009) Strategies to improve the geometric accuracy in asymmetric single point incremental forming. Prod Eng 3(2):145–156

    Article  Google Scholar 

  14. Ambrogio G, Filice L, Manco G (2008) Considerations on the incremental forming of deep geometries. Int J Mater Form 1:1143–1146

    Article  Google Scholar 

  15. Ma LW, Mo JH (2008) Three-dimensional finite element method simulation of sheet metal single-point incremental forming and the deformation pattern analysis. Proc Inst Mech Eng B: J Eng Manuf 222(3):373–380

    Article  Google Scholar 

  16. Essa K, Hartley P (2010) An evaluation of shear deformation mechanisms in single point incremental forming using a dual-level finite-element model. Submitted to CIRP Journal of Manufacturing Science and Technology, May

  17. Essa K, Hartley P (2010) Investigation on the effects of process parameters on the through-thickness shear strain in single point incremental forming using dual level FE modelling and statistical analysis. Accepted for publication in the Journal of Computer Methods in Materials Science

  18. Hussain G, Gao L (2007) A novel method to test the thinning limits of sheet metals in negative incremental forming. Int J Mach Tools Manuf 47(3–4):419–435

    Article  Google Scholar 

  19. Bambach M, Hirt G, Junk S (2003) Modelling and experimental evaluation of the incremental CNC sheet metal forming process. In: Proceedings of the 7th International Conference on Computational Plasticity. Barcelona, Spain, pp 1–17

Download references

Acknowledgments

The financial support of the UK Overseas Research Students Awards Scheme (K Essa) is gratefully acknowledged.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, College of Engineering and Physical Sciences, University of Birmingham, Edgbaston, Birmingham, B15 2TT, UK

    Khamis Essa & Peter Hartley

Authors
  1. Khamis Essa
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Peter Hartley
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Peter Hartley.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Essa, K., Hartley, P. An assessment of various process strategies for improving precision in single point incremental forming. Int J Mater Form 4, 401–412 (2011). https://doi.org/10.1007/s12289-010-1004-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12289-010-1004-9

Keywords

Search

Navigation