Papers by Keyword: Forming Tool

Abstract: The Single Point Incremental Forming Process (SPIF) is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped. The finished part is manufactured by the CNC machine. SPIF involves extensive plastic deformation and the description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. However, due to the complex nature of these models, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study on effect of using cover blank in SPIF through FEA. The considered SPIF has been studied under certain process conditions referring to the test work piece, tool, etc., applying ANSYS 11.0. The results show that the simulation model can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool-work piece, the product accuracy by evaluation its thickness and strain distributions, the contact status and chattering among surface interface tool-work piece.

Abstract: The Single Point Incremental Forming Process, SPIF, is a forming technique of sheet material based on layered manufacturing principles. The forming tool is moved along the tool path while the edges of sheet material are clamped on fixture by holder. The finished part is performed by the CNC milling machine. The description of the process is more complicated by highly nonlinear boundary conditions, namely contact and frictional effects have been accomplished. Due to the fact that the mathematical analysis of SPIF is complex, numerical approaches dominated by the FEA are now in widespread use. The paper presents the data and main results of a study concerning the effect of forming tool profile on SPIF through FEA, that permits the modeling of complex geometries, material behavior and boundary conditions. SPIF has been studied under certain process conditions referring to the test workpiece, tool, etc., using ANSYS 11.0. The results showed that the model of simulation can predict an ideal profile of processing track, spring back error of SPIF, the behavior of contact tool - workpiece, the accuracy of product by evaluation the strain and the stress distributions between forming tool and workpiece surface interface, and sample of results have been demonstrated.

Abstract: The main aim of the study was to develop forming tools for wide (over 1.2 meter) sandwich panels. Longitudinal laminating technology was selected for tool manufacturing due to its flexibility and cost efficiency. Laminating technology enables easy modification of the tool dimensions afterwards. The function to optimize or vary the dimensions of the tool was set as a secondary objective for the study. Forming tools for sandwich panels are usually complicated structures and joining of the plates can be difficult in some cases. Typically sandwich forming tools are capable to produce only narrow panels (less than 1 meter) and optimization must be done during designing of the tool. In this study, a rapid designing and manufacturing of a flexible sandwich panel forming tool was investigated. Sandwich panels are usually applied in light structures or voice covers due to their very low weight, high stiffness, durability and production cost savings. Designing of the forming tool was made by using a 3D CAD program. Conventional steel plates were used for the forming tool and the assembly was done by fixing the plate parts longitudinally together (laminating). Most important criterion for the forming tool was its capability to produce high quality geometry for the core. Laser welding assembly showed that the quality of the core was good enough for welding the lap joints properly. Both of the objectives were fulfilled: 1) forming tools were suitable for forming of wide cores (1.2 meter) and 2) the structure of the laminated tool enables to change or add new plate parts to change the dimensions of the final product.

Abstract: This work addresses through bibliographies and experiments the behavior of sheet brass 70/30 for Incremental Sheet Forming process - ISF, based on the parameters: wall angle (), step vertical (ΔZ) strategy and the way the tool. Experiments based on the method called Single Point Incremental Forming - SPIF. For execution of practical tests, we used the resources: software CAD / CAM, CNC machining center with three axles, matrix incremental, incremental forming tool and a device press sheets. Furthermore, measurement was made of the true deformation () and thickness (s1). Practical tests have shown that the spiral machining strategy yielded a greater wall angle, compared to the conventional strategy outline.

Abstract: In the automotive industry, current design and dimensioning of forming tools and bearing tool components occurs according to guidelines. Possible interactions between arising loads as well as dimensioning are empirically estimated. Simulative computations, which are based on CAE-methods, are only realized in special cases. Therefore, most often current standards lead to oversized tools. In consequence, new studies based on CAE-analyses are supposed to investigate new possibilities to design forming tools and components optimized in their structure corresponding to the right distribution of forces and stress. This is made in order to increase reliability during the manufacturing process, as well as the tools’ stiffness and contribute to decrease of investment costs.

Abstract: Semi-solid processing of materials provides advantages of both forging and casting. Experiments with high-melting and biocompatible alloys aiming at a “near-net-shape” production technology recently have been conducted. Advanced trials showed, that processing of such materials by means of semi-solid forming deliver a huge potential for feasible workpiece shapes and drastically reduces machining time and subsequent surface treatment efforts. In contrast to semi-solid forming of aluminium alloys at relatively low temperature levels any processing of high-melting point alloys in the semi-solid state is much more challenging due to higher forming temperature. Commonly used tool materials provoke high wear rates due to wetting, bonding and melting processes which finally result in a very short tool life time. Thus, more apt materials and composites for forming tools and dies which can withstand corrosion, wear, tear and extreme changes in temperatures have to be found. The development of new design concepts for long-living close-to-production tools based on such new materials will be a future goal.

Abstract: Deep drawing of high strength steels imposes high tribological requirements on forming tools. Thermal spraying is regarded as a promising technology to improve the tool’s performance and the service life of the forming tool, as long as ambitious demands of the coating process are matched. In order to qualify a thermal spraying process for a surface technology in deep drawing it is crucial that the coating obtains an extremely dense structure and a smooth, near-net-shape surface. The study presented considers two different approaches to achieve those goals. The application of fine-scaled powders (<10$m) spraying through HVOF technique offers the opportunity to deposit dense coatings with very smooth surfaces. In contrast, it is also feasible to achieve very smooth and dense coatings by combining conventional powders with a subsequently densification procedure

Abstract: Multifunctional coatings open new dimensions due to a combination of properties like high friction and wear resistance, electrical attributes, heat or corrosion protection in one system. In this study multifunctional coatings for in-situ temperature measurements on cutting inserts as well as multilayer coatings have been investigated. Corresponding metallurgical analyses together with mechanical tests are presented.