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Effect of generatrix profile on single-point incremental forming parameters

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Abstract

The single-point incremental forming is one of two modes of the incremental sheet forming process. It is the most used in the manufacture of parts for small series and prototypes in various sectors such as aeronautics, biomedical field, and art pieces. In this work, two geometries of parts are investigated at the same process parameters (rotation speed, feed rate, step increment, sheet thickness, and tool diameter). The experimental tests are made with a CNC spinner milling machine. The blank sheet of mild steel is formed by means of a hemispherical tool with a 10-mm diameter. The forming tool follows the desired spiral path that is determined by a CAD model. The main objective of this paper is to study the effects of the generatrix profile for two shapes of a truncated cone (straight and circular generatrix) on forming forces, thickness distribution, shape accuracy, and surface roughness of the formed shape. Besides, a coefficient of shape is introduced from experimental and analytical vertical forces. The experimental results show that a better roughness surface quality is obtained in forming a straight generatrix and that a more uniform thickness distribution of the blank is obtained after thinning and shaping a circular generatrix. In order to examine the geometric accuracy of the parts, a Next Engine 3D scanner is used to rebuild the developed surfaces again and to make a comparison between the programmed and scanned profiles.

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Authors and Affiliations

  1. Mechanical Laboratory of Sousse, National Engineering School of Sousse, University of Sousse, BP 264, Sousse Erriadh, Tunisia

    Mariem Dakhli & Zoubeir Tourki

  2. National Institute of Applied Science and Technology, Centre Urbain Nord, University of Carthage, BP 676 - 1080, Tunis Cedex, Tunisia

    Atef Boulila

Authors
  1. Mariem Dakhli
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  2. Atef Boulila
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  3. Zoubeir Tourki
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Correspondence to Mariem Dakhli.

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Dakhli, M., Boulila, A. & Tourki, Z. Effect of generatrix profile on single-point incremental forming parameters. Int J Adv Manuf Technol 93, 2505–2516 (2017). https://doi.org/10.1007/s00170-017-0598-1

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  • DOI: https://doi.org/10.1007/s00170-017-0598-1

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