Abstract
Incremental sheet forming with active medium (IFAM) is a modification of the well-known single point incremental forming (SPIF) and allows convex forming operations by applying pressure of an active medium on the bottom surface of the blank. Both convex and concave forming can be combined to a multi-stage forming strategy when the part is turned between these two forming steps. Experiments on a truncated pyramid are conducted to evaluate the influence of the two-stage forming strategy on the geometrical accuracy in comparison with an equivalent single-stage forming strategy. The findings indicate that the height of the convex preform has a major impact on the final accuracy. If the height of preform amounts 75% of the target height, the undesired bending in the flange region is significantly reduced and can be explained by a decreased vertical forming force. This effect leads to an increased geometrical accuracy in contrast to single-stage SPIF.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Jeswiet, J., Micari, F., Hirt, G., Bramley, A., Duflou, J., Allwood, J.: Asymmetric single point incremental forming of sheet metal. CIRP Ann. 54(2), 88–114 (2005)
Ambrogio, G., De Napoli, L., Filice, L.: A novel approach based on multiple back-drawing incremental forming to reduce geometry deviation. In: 12th International ESAFORM Conference on Material Forming, International Journal of Material Forming, vol. 2, pp. 9–12 (2009)
Jadhav, S.: Basic investigations of the incremental sheet metal forming process on a CNC milling machine. Dissertation, University of Dortmund (2004)
Hirt, G., Ames, J., Bambach, M., Kopp, R.: Forming strategies and process modelling for CNC incremental sheet forming. CIRP Ann. 53(1), 203–206 (2004)
Micari, F., Ambrogio, G., Filice, L.: 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 (2007)
Maqbool, F., Bambach, M.: Dominant deformation mechanisms in single point incremental forming (SPIF) and their effect on geometrical accuracy. Int. J. Mech. Sci. 136, 279–292 (2018)
Bambach, M., Taleb Araghi, B., Hirt, G.: Strategies to improve the geometric accuracy in asymmetric single point incremental forming. Prod. Eng. Res. Develop. 3, 145–156 (2009)
Ambrogio, G., De Napoli, L., Filice, L., Micari, F., Muzzupappa, M.: Some considerations on the precision of incrementally formed double-curvature sheet components. In: 9th International ESAFORM Conference on Material Forming, pp. 199–202 (2006)
Formisano, A., Durante, M., Langella, A., Capece Minutolo, F.: A comparison between two incremental forming processes for the achievement of a component with concave–convex shape. In: 4th Virtual Conference on Innovative Production Machines and Systems, pp. 498–503 (2008)
Meier, H., Smukala, V., Dewald, O., Zhang, J.: Two point incremental forming with two moving forming tools. In: 12th International Conference on Sheet Metal, Key Engineering Materials, vol. 344, pp. 599–605 (2007)
Meier, H., Magnus, C., Smukala, V.: Impact of superimposed pressure on dieless incremental sheet metal forming with two moving tools. CIRP Ann. 60(1), 327–330 (2011)
Thiery, S., Zein El Abdine, M., Heger, J., Ben Khalifa, N.: Closed-loop control of product geometry by using an artificial neural network in incremental sheet forming with active medium. Int. J. Mater. Form. (2020). https://doi.org/10.1007/s12289-020-01598-1
Ben Khalifa, N., Thiery, S.: Incremental sheet forming with active medium. CIRP Ann. 68(1), 313–316 (2019)
McLoughlin, K., Cognot, A., Quigley, E.: Dieless manufacturing of sheet metal components with non rigid support. In: 10th International Conference on Sheet Metal, pp. 123–130 (2003)
Taleb Araghi, B., Bambach, M., Hirt, G.: Comparison of some final part geometrical characteristics of cylindrical cups manufactured by deep-drawing and two-point incremental sheet forming. In: 13th International Conference on Sheet Metal, Key Engineering Materials, vol. 410, pp. 355–363 (2009)
Kitazawa, K., Nakajima, A.: Cylindrical incremental drawing of sheet metals by CNC incremental forming process. In: 6th International Conference on the Technology of Plasticity, pp. 1495–1500 (1999)
Verbert, J., et al.: Multi-step toolpath approach to overcome forming limitations in single point incremental forming. In: 11th International ESAFORM Conference on Material Forming, International Journal of Material Forming, vol. 1, no. 1, pp. 1203–1206 (2008)
Skjoedt, M., Silva, M.B., Martins, P.A.F., Bay, N.: Strategies and limits in multi-stage single-point incremental forming. J. Strain Anal. Eng. Des. 45(1), 33–44 (2010)
Li, Z., Lu, S., Zhang, T., Mao, Z., Zhang, C.: Analysis of geometrical accuracy based on multistage single point incremental forming of a straight wall box part. Int. J. Adv. Manuf. Technol. 93(5), 2783–2789 (2017)
Young, D., Jeswiet, J.: Wall thickness variations in single-point incremental forming. J. Eng. Manuf. 218(11), 1453–1459 (2004)
Shamsari, M., Mirnia, M.J., Elyasi, M., Baseri, H.: 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 (2018)
Acknowledgements
The authors would like to thank the German Research Foundation (DFG) for financially supporting this research project under the grant number BE 5196/14-1.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2022 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Thiery, S., Ben Khalifa, N. (2022). Geometrical Accuracy in Two-Stage Incremental Sheet Forming with Active Medium. In: Behrens, BA., Brosius, A., Drossel, WG., Hintze, W., Ihlenfeldt, S., Nyhuis, P. (eds) Production at the Leading Edge of Technology. WGP 2021. Lecture Notes in Production Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-78424-9_8
Download citation
DOI: https://doi.org/10.1007/978-3-030-78424-9_8
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-78423-2
Online ISBN: 978-3-030-78424-9
eBook Packages: EngineeringEngineering (R0)