Critical analysis of necking and fracture limit strains and forming forces in single-point incremental forming |
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| Affiliation: | 1. Department of Mechanical and Manufacturing Engineering, University of Seville, Camino de los Descubrimientos s/n, 41092 Sevilla, Spain;2. Department of Mechanical Engineering and Industrial Construction, University of Girona, C/Maria Aurèlia Capmany, 61. 17071 Girona, Spain;1. Department of Industrial Engineering, King Abdulaziz University, Jeddah, Saudi Arabia;2. Department of Mechanical Engineering, Eastern Mediterranean University, N. Cyprus Via Mersin-10, Turkey;1. Department of Mechanical Engineering, Oregon State University, United States;2. Department of Industrial Engineering, Oregon State University, United States;3. Department of Automotive Engineering, Clemson University, United States;4. Department of Materials Science and Engineering, Clemson University, United States;1. Faculty of Engineering and Industrial Sciences, Swinburne University of Technology, Melbourne, VIC 3122, Australia;2. Dept. of Mechanical and Automotive Eng., Seoul National Univ. of Tech., Seoul 139-743, Republic of Korea;3. General Motors Global Research and Development Center, MC 480-106-244, Warren, MI 48090-9055, USA;4. School of Engineering & Institute for Frontier Materials, Deakin University, Geelong Waurn Ponds, VIC 3220, Australia;1. University of Girona, Department of Mechanical Engineering and Industrial Construction, Girona, Spain;2. University of Seville, Department of Mechanical and Manufacturing Engineering, Sevilla, Spain;3. Instituto Tecnológico y de Estudios Superiores de Monterrey, Departamento de Ingeniería Mecánica, Monterrey, Mexico |
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| Abstract: | Single-Point Incremental Forming (SPIF) is an emerging manufacturing process especially suitable to produce small batches of metal parts. Moreover, the enhanced formability of metal sheets deformed by SPIF makes this technology useful to those industrial applications requiring high deformation levels. In this sense, the precise setting of limit strains in SPIF in relation to the conventional formability limits of the material, as well as the influence of the process parameters on these strains, are essential variables to understand how and how much can be deformed the metal sheets in real production. On the other hand, the forming force in SPIF is an essential variable, especially for the design of dedicated equipment or for the safe use of adapted machinery. This paper revisits failure in SPIF by means of an experimental analysis of the influence of process parameters, such as the tool diameter, the spindle speed and the step down, on the formability in SPIF (spifability) of AISI 304 metal sheets, studied in the light of circle grid analysis. The work also involves the independent determination of conventional formability limits by necking and fracture under laboratory conditions by using stretching tests (Nakazima tests), in conjunction with stretch-bending tests performed in order to quantify the influence of the bending induced by the tool radius. Failure strains are experimentally obtained and compared in stretch-bending and SPIF tests, being the failure mode discussed in each case. Finally, the axial forming force evolution was recorded with the aim of analyzing the range of process parameters that would guarantee the safely utilization of the non-dedicated process equipment. |
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| Keywords: | Single-point incremental forming Forming force Formability limits Spifability Bending effect |
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