Paper Titles
Effect of Difference of Tool Rotation Direction on Forming Limit in Friction Stir Incremental Forming
p.390
Experimental Study on the Incremental Forming of Coated Aluminum Alloy Sheets
p.398
Impact of High Speed Incremental Forming on Material Properties of AA6082 Sheets
p.406
Innovative Machine Design for Incremental Profile Forming
p.413
Single Point Incremental Sheet Forming of Polymer on Computer Numerically Controlled (CNC) Milling Machine Tool
p.420
Strain Analysis of Parts Produced by Multi-Pass Conventional Metal Spinning
p.427
High-Speed Single Point Incremental Forming of an Automotive Aluminium Alloy
p.433
A Cohesive Zone Model for Simulation of the Bonding and Debonding in Metallic Composite Structures - Experimental Validations
p.443
Adhesion Strength Study of Silicone Rubber Compounds to Nylon 66
p.453

Single Point Incremental Sheet Forming of Polymer on Computer Numerically Controlled (CNC) Milling Machine Tool

Article Preview

Abstract:

The idea of incrementally forming sheet metal with a single point tool, called ‘dieless forming’, was patented by Leszak [1] well before it was technically feasible. There have been many studies, which have lead to the present situation [2-9]. The new processes are attractive because manufacturing sheet metal can be accomplished by any facility having a three-axis cnc mill. Sheet metal spif is an innovative, flexible sheet metal-forming technology that uses principles of layered manufacturing. It transforms the complicated geometry information into a series of parameter of two-dimensional layers and then the plastic deformation is carried out layer-by-layer through the computer numerically controlled. The basic principle of spif (Fig. 1) is that the forming tool moves around the outline of the part along the predefined tool path and extrudes the sheet metal point by point so that the local plastic deformations occur incrementally [8, 10]. The forming tool paths have a great effect on the surface quality, forming time and dimensional accuracy. Although the movement mode of the forming tool is similar to one of the cutters in the cnc milling machine, the forming process based on the plastic deformation and milling process is totally different, so the requirements for the tool paths are different. As a result, there are some specific characteristics which should be considered in forming tool path generation. The goal of this paper is to evaluate the possibility of producing low-cost polymer sheet components by means of spif. Three different thermoplastic materials were incrementally formed on a conventional cnc milling machine. Experiments are conducted to determine the formability, failure modes and significant process parameters. Even though considerable amount of research work has been done in the field, these aspects are not completely defined and only limited number of materials has been tested.

You might also be interested in these eBooks
Metal Forming 2014 View Preview

Info:

Periodical:

Key Engineering Materials (Volumes 622-623)

Pages:

420-426

DOI:

https://doi.org/10.4028/www.scientific.net/KEM.622-623.420

Citation:

Cite this paper

Online since:

September 2014

Authors:

D. Rajenthirakumar*, R. Sridhar

Keywords:

Computer Numerically Controlled Machine, Formability, Incremental Sheet Forming, Polymer, Spring Back Effect, Wall Angle

Export:

RIS, BibTeX

Price:

Permissions CCC:

Request Permissions

Permissions PLS:

Request Permissions

Сopyright:

© 2014 Trans Tech Publications Ltd. All Rights Reserved

Share:

Citation:

* - Corresponding Author

References

[1] E. Leszak, Patent US3342051A1, Apparatus and Process for Incremental Dieless Forming, (1967) 09-19.

Google Scholar

[2] H. Müller, H. Enzmann, Potentials of Rapid Prototyping Techniques for the Manufacture of Prototype Sheet Metal Forming Tools, Proc. European Conf. on Rapid Prototyping and Manufacturing, Aachen, (1998)337-350.

Google Scholar

[3] D. H. Müller, H. Müller, Experiences using Rapid Prototyping Techniques to Manufacture Sheet Metal Forming Tools, Proc. ISATA Conference, Dublin, (2000) 9.

Google Scholar

[4] T. H. Jørgensen, N. Moos, Applications of RP Techniques for Sheet Metal Forming, State-of-the- Art, RAPTIA Thematic Network report, (2002).

Google Scholar

[5] T. Nakagawa, Recent Developments in Auto Body Panel Forming Technology, Annals of the CIRP, 42(2) (1993) 13-317.

DOI: 10.1016/s0007-8506(07)62534-7

Google Scholar

[6] V. Franke, W. Greska, M. Geiger, Laminated Tool System for Press Brakes, Proceedings of 26th International CIRP Seminar on Manufacturing Systems - LANE '94, Meisenbach, (1994) 883-892.

Google Scholar

[7] T. Himmer, A. Techel, S. Nowotny, E. Beyer, Recent Developments in Metal Laminated Tooling by Multiple Laser Processing, Proc. Internat. User's Conf. on Rapid Prototyping, Rapid Tooling & Rapid Manufacturing, Frankfurt, (2002) B-5/3.

DOI: 10.1108/13552540310455629

Google Scholar

[8] J. J. Park, Y. H. Kim, Fundamental studies on the incremental sheet metal forming technique. J Mater Process Technol, 140 (2003) (1-3): 447-453.

Google Scholar

[9] E. Hagan, J. A. Jeswiet, A review of conventional and modern single-point sheet metal forming methods. J Eng Manufact, 217 (2) (2003) 213–225.

DOI: 10.1243/095440503321148858

Google Scholar

[10] J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, J. Allwood, Asymmetric single point incremental forming of sheet metal. CIRP Ann, 54(2) (2005) 623–649.

DOI: 10.1016/s0007-8506(07)60021-3

Google Scholar

[11] A. E. Tekkaya, P.A.F. Martins, L. Kwiatkowski, V. Franzen, M. Kleiner, Single point incremental forming of polymers, CIRP Annals - Manufacturing Technology, 58 (2009) 229–232.

DOI: 10.1016/j.cirp.2009.03.095

Google Scholar

[12] M. Ham, J. Jeswiet, Single Point Incremental Forming Limits Using A Box- Behnken Design of Experiment, Key Engineering Materials, 344 (2007) 629–636.

DOI: 10.4028/www.scientific.net/kem.344.629

Google Scholar

[13] Joost Duflou, Yasemin Tunckol, Experimental study on force measurements for single point incremental forming, Journal of Material Processing Technology, 189(2007) 65-72.

DOI: 10.1016/j.jmatprotec.2007.01.005

Google Scholar

[14] Ham M, Jeswiet J, Single point incremental forming limits using a Box- Behnken design of experiment, Key Engineering Materials 344 (2007) 629–636.

DOI: 10.4028/www.scientific.net/kem.344.629

Google Scholar