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Joule heating of the forming zone in incremental sheet metal forming: Part 2

Creating an experimental setup and forming of Ti6Al4V

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Abstract

Incremental sheet metal forming at elevated temperatures takes the approach to positively influence the forming properties of the processed material. Among others, the influenced key attributes of the final part are geometric accuracy, the usable material, and the residual stresses after forming. In the first part of this paper, a state of the art analysis of used heating methods and a thermal process model for Joule heating have already been presented. This second part describes the development of an experimental setup and shows results of forming of Ti6Al4V sheets.

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Abbreviations

AISF –:

Asymmetric incremental sheet forming

DC –:

Direct current

DPIF –:

Duplex incremental forming

DPIF-L –:

Duplex incremental forming with local support

DPIF-P –:

Duplex incremental forming with peripheral support

fts –:

Force-torque-sensor

HSS –:

High speed steel

IFOV –:

Instantaneous field of view

ISF –:

Incremental sheet forming

KRL –:

KUKA robot language

KXF –:

A special grade of tungsten carbide

PLC –:

Programmable logic controller

RPS –:

Reference point system

RSI –:

Robot sensor interface

SPIF –:

Single point incremental forming

TCP –:

Tool-center-point

USB –:

Universal serial bus

μ C –:

Microcontroller

\(A_{\mathrm {5d}}~[\mathrm {\frac {N}{mm^{2}}}]\) :

Elongation at rupture (specimen’s length was five times as long as the initial diameter)

\(c_{p}~[\frac {\mathrm {J}}{\text {kg}\cdot \mathrm {K}}]\) :

Specific heat capacity

\(E~[\frac {\mathrm {N}}{\text {mm}^{2}}]\) :

Young’s modulus

F [N]:

Force

F res [N]:

Resultant of force vector

\(g~[\frac {\mathrm {m}}{\mathrm {s}^{2}}]\) :

Gravitational acceleration

\(\bar {I}~[\mathrm {A}]\) :

Mean value of electric current

\(k~[\frac {\text {mm}^{3}{\mathrm {N}\cdot \mathrm {m}}}]\) :

Wear coefficient

l [m]:

length

L B K [−]:

Material-specific light weight factor

L B K z [−]:

Material-specific light weight factor (tension)

r (mm):

Radius

\(R_{\mathrm {m}}~[\frac {\mathrm {N}}{\text {mm}^{2}}]\) :

Ultimate tensile strength

\(R_{\mathrm {p0.2}}~[\frac {\mathrm {N}}{\text {mm}^{2}}]\) :

0.2 % offset yield strength

s [m]:

Sliding distance

t [s]:

Time

t B0 [mm]:

Initial sheet thickness

\(v~[\frac {\mathrm {m}}{\mathrm {s}}]\) :

Tool speed

W v [mm3]:

Volumetric wear rate

z t [mm]:

Step size in z direction

α [°]:

Wall angle

\(\alpha _{A}~[\frac {1}{\mathrm {K}}]\) :

Coefficient of linear expansion

𝜖 [−]:

Emissivity

𝜗 [°C]:

Temperature

𝜗 fz [°C]:

Temperature of the forming zone

𝜗 S [°C]:

Melting point

𝜗 U [°C]:

Temperature of the surrounding atmosphere

𝜗 1 [°C]:

Start temperature

\(\lambda ~[\frac {\mathrm {W}}{\mathrm {m}\cdot \mathrm {K}}]\) :

Thermal conductivity

ρ [Ω ⋅ m]:

Resistivity

\(\rho _{s}~[\frac {\text {kg}}{\mathrm {m}^{3}}]\) :

Density of the sheet material

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Authors and Affiliations

  1. Chair of Production Systems (LPS), Ruhr-Universität Bochum, 44801, Bochum, Germany

    Christian S. Magnus

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Magnus, C.S. Joule heating of the forming zone in incremental sheet metal forming: Part 2. Int J Adv Manuf Technol 89, 295–309 (2017). https://doi.org/10.1007/s00170-016-9008-3

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