The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic s...The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.展开更多
This study performs single point incremental forming(SPIF)on two aluminum alloys(i.e.AA5754 and AA6061),and analyzes their post forming mechanical properties and microstructure evolution.The forming parameters namely ...This study performs single point incremental forming(SPIF)on two aluminum alloys(i.e.AA5754 and AA6061),and analyzes their post forming mechanical properties and microstructure evolution.The forming parameters namely wall angle(35°-55°),feed rate(1-4 m/min),spindle rotational speed(50-1000 r/min),and lubricant(grease and hydraulic oil)are varied to probe detailed processing effects.The pre-and post-SPIF mechanical properties and microstructures are characterized by conducting tensile tests and optical microscopy,respectively.It is shown that an increase in the wall angle,feed rate and rotational speed causes microscopic variations in the alloys such that the grains of AA5754 and the second phase particles of AA6061 elongate.As a result,the ultimate tensile strength of the formed parts is increased by 10%for AA5754 and by 8%for AA6061.And,the ductility of AA5754 is decreased from 22.9%to 12%and that of AA6061 is decreased from 16%to 10.7%.Regarding the lubricant effect,it is shown that the mechanical properties remain insensitive to the type of lubricant employed.These results indicate that SPIF processing modifies the microstructure of Al alloys in a way to enhance the strength at the cost of ductility.展开更多
The influence of the size of pre-cut hole of blank on the formability of cylindrical hole flanging in single point incremental forming（SPIF） was studied. The flange is produced in four stages starting from 45° ...The influence of the size of pre-cut hole of blank on the formability of cylindrical hole flanging in single point incremental forming（SPIF） was studied. The flange is produced in four stages starting from 45° to 90° and employing aluminum as the test material. It is shown that the hole size has significant effects on the stress/strain distribution on the cylindrical flange. The magnitude of hoop strains increases and the flange thickness increases as the hole size increases. Likewise, the von Mises stress reduces with the increasing of hole size. Further, there is a threshold value of hole size（i.e., 80 mm） below which severe stresses occur, which lead to sheet fracturing thus failing the successful forming of cylindrical flange. Moreover, the formability reduces as the hole size is increased above the threshold size. Finally, it is concluded that 80 mm is the threshold size of hole for maximizing the formability of aluminum sheet in incremental hole flanging.展开更多
Incremental forming process is recently developed to form tubular parts.The fabrication cost and accuracy could be optimized if the effects of process parameters and the optimum values are specified.The aim of this re...Incremental forming process is recently developed to form tubular parts.The fabrication cost and accuracy could be optimized if the effects of process parameters and the optimum values are specified.The aim of this research is using incremental forming of copper tubes to convert a circular tube into a square cross-sectional part.An experimental setup,consisting of a spherical forming punch and a fixture for clamping the tube is designed.The forming punch movement is controlled by a CNC machine.Full factorial design of experiments is carried out in order to determine the effects of process parameters including linear velocity,radial feed,and axial feed of the tool on the thinning ratio and the maximum outer diameter of the square cross-sectional parts.Results show that the radial feed has the major influence on the thinning ratio,while the axial feed plays the major role for the final profile.Increase of radial feed results in higher thinning ratio,and decrease of axial feed results in better shape conformity.Linear velocity does not have a significant effect on thinning ratio.Regression models are also given for predicting the determined responses.展开更多
The research of forming parameters on the ultrasonic vibration single-point incremental forming of magnesium alloy plastic deformation can provide a theoretical basis for the establishment of the forming parameters.Ac...The research of forming parameters on the ultrasonic vibration single-point incremental forming of magnesium alloy plastic deformation can provide a theoretical basis for the establishment of the forming parameters.According to the forming characteristics of magnesium alloy sheet,a new method of ultrasonic vibration-as sis ted single-point incremental forming was proposed.The influence of forming parameters on the plastic deformation of magnesium alloy was studied by finite element simulation and experimentation.The influence of vibration frequency,amplitude,friction coefficient,and tool head size on stress and thinning rate of magnesium alloy during ultrasonic vibration-as sis ted single-point asymptotic forming was studied.The results show that the vibration frequency of 20 kHz and forming tool radius of about 5 mm are beneficial for plastic deformation magnesium alloy in ultrasonic vibration-assisted single-point incremental forming.With vibration amplitude increasing,the maximum shear stress tends to decrease as a whole,but at the amplitude of 0.16 mm,the thinning rate is large and fracture occurs easily.With friction coefficient increasing,the maximum shear stress tends to increase,and there is a good linear relationship between the maximum thinning rate and the friction coefficient.展开更多
Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation a...Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.展开更多
A method utilizing variable depth increments during incremental forming was proposed and then optimized based on numerical simulation and intelligent algorithm.Initially,a finite element method(FEM) model was set up a...A method utilizing variable depth increments during incremental forming was proposed and then optimized based on numerical simulation and intelligent algorithm.Initially,a finite element method(FEM) model was set up and then experimentally verified.And the relation between depth increment and the minimum thickness tmin as well as its location was analyzed through the FEM model.Afterwards,the variation of depth increments was defined.The designed part was divided into three areas according to the main deformation mechanism,with Di(i=1,2) representing the two dividing locations.And three different values of depth increment,Δzi(i=1,2,3) were utilized for the three areas,respectively.Additionally,an orthogonal test was established to research the relation between the five process parameters(D and Δz) and tmin as well as its location.The result shows that Δz2 has the most significant influence on the thickness distribution for the corresponding area is the largest one.Finally,a single evaluating indicator,taking into account of both tmin and its location,was formatted with a linear weighted model.And the process parameters were optimized through a genetic algorithm integrated with an artificial neural network based on the evaluating index.The result shows that the proposed algorithm is satisfactory for the optimization of variable depth increment.展开更多
Single point incremental forming(SPIF)is an innovative sheet forming process with a high economic pay-off.The formability in this process can be maximized by executing forming with a tool of specific small radius,rega...Single point incremental forming(SPIF)is an innovative sheet forming process with a high economic pay-off.The formability in this process can be maximized by executing forming with a tool of specific small radius,regarded as threshold critical radius.Its value has been reported as 2.2 mm for 1 mm thick sheet materials.However,with a change in the forming conditions specifically in the sheet thickness and step size,the critical radius is likely to alter due to a change in the bending condition.The main aim of the present study is to undertake this point into account and develop a relatively generic condition.The study is composed of experimental and numerical investigations.The maximum wall angle(θmax)without sheet fracturing is regarded as sheet formability.A number of sheet materials are formed to fracture and the trends correlating formability with normalized radius(i.e.,R/To where R is the tool-radius and To is the sheet thickness)are drawn.These trends confirm that there is a critical tool-radius(Rc)that maximizes the formability in SPIF.Furthermore,it is found that the critical radius is not fixed rather it shows dependence on the sheet thickness such that Rc=βTo,whereβvaries from 2.2 to 3.3 as the thickness increases from 1 mm to 3 mm.The critical radius,however,remains insensitive to variation in step size ranging from 0.3 mm to 0.7 mm.This is also observed that the selection of tool with R<Rc narrows down the formability window not only on the higher side but also on the lower side.The higher limit,as revealed by the experimental and FEA results,diminishes due to excessive shearing because of in-plane biaxial compression,and the lower limit reduces due to pillowing in the bottom of part.The new tool-radius condition proposed herein study would be helpful in maximizing the formability of materials in SPIF without performing experimental trials.展开更多
Although multi-stage incremental sheet forming has always been adopted instead of single-stage forming to form parts with a steep wall angle or to achieve a high forming performance, it is largely dependent on empiric...Although multi-stage incremental sheet forming has always been adopted instead of single-stage forming to form parts with a steep wall angle or to achieve a high forming performance, it is largely dependent on empirical designs. In order to research multi-stage forming further, the effect of forming stages(n) and angle interval between the two adjacent stages(Δα) on thickness distribution was investigated. Firstly, a finite element method(FEM) model of multi-stage incremental forming was established and experimentally verified. Then, based on the proposed simulation model, different strategies were adopted to form a frustum of cone with wall angle of 30° to research the thickness distribution of multi-pass forming. It is proved that the minimum thickness increases largely and the variance of sheet thickness decreases significantly as the value of n grows. Further, with the increase of Δα, the minimum thickness increases initially and then decreases, and the optimal thickness distribution is achieved with Δα of 10°.Additionally, a formula is deduced to estimate the sheet thickness after multi-stage forming and proved to be effective. And the simulation results fit well with the experimental results.展开更多
To solve the problems of poor forming and easy adhesion of the stainless steel,Cu alloyed layer on the stainless steels was prepared by the double glow plasma surface alloying technique.The experimentalresults indicat...To solve the problems of poor forming and easy adhesion of the stainless steel,Cu alloyed layer on the stainless steels was prepared by the double glow plasma surface alloying technique.The experimentalresults indicated that the supersaturated copper dispersedly precipitated in grain interior and crystalboundaries and formed the vermicular structure.The tribologicaltests indicated that the friction coefficient of the Cu alloyed layer was lower than that of the stainless steels.The wear rate of stainless steelin the presence of Cu alloyed layer was approximately 2-fold lower than that in the absence of the alloyed layer.The results of the incrementalforming indicated that the ploughing phenomenon was not observed on the stainless steelin the presence of Cu alloyed layer during the incrementalforming,while the stainless steelpresented the deep ploughing.Therefore,Cu alloyed layer on stainless steelexhibited excellent self-lubrication and forming properties.展开更多
By friction heating single point incremental forming,truncated square pyramid parts with different draw angles of a magnesium alloy AZ31 B were formed at room temperature.Metallurgical,tensile and micro-hardness tests...By friction heating single point incremental forming,truncated square pyramid parts with different draw angles of a magnesium alloy AZ31 B were formed at room temperature.Metallurgical,tensile and micro-hardness tests were carried out to obtain the effects of wall angle on microstructure and mechanical properties. The results show that grain in side wall of the formed parts becomes refined significantly. Furthermore,with the increase of draw angle,grain size increases,but strength,hardness and plasticity decrease. In addition, surface roughness tests were performed on the formed surface to determine the influence of speed of forming tool. The results show that surface roughness has a little increase with the increase of tool rotational speed.展开更多
Sheet metal single point incremental forming （SPIF） is a new technology for flexible process. The springback phenomenon in single point incremental forming has been discussed. Effects of forming angle and shape of t...Sheet metal single point incremental forming （SPIF） is a new technology for flexible process. The springback phenomenon in single point incremental forming has been discussed. Effects of forming angle and shape of the part are analysed using simple experimental method. Tool diameter, sheet thickness, step size, material parameters and the interaction of them are also analysed by using orthogonal test. The results show that the primary factor af- fecting springback is forming angle. In addition, springback is decreased when the specimen has a larger forming angle. The order of the four factors that influence springback is tool diameter, sheet thickness, step size and material parameters. The forming precision will increase if springabck is decreased by optimizing the forming parameters.展开更多
With the generation of both localised thermal and vibration in incremental sheet forming(ISF)by novel tool designs,rotational vibration assisted ISF(RV-ISF)can achieve significant force reduction and material softenin...With the generation of both localised thermal and vibration in incremental sheet forming(ISF)by novel tool designs,rotational vibration assisted ISF(RV-ISF)can achieve significant force reduction and material softening.However,the combined thermal and vibration softening in RV-ISF is unclear.By evaluating the similarities and differences of friction stir ISF(FS-ISF)and RV-ISF,this study develops a novel approach to decouple and quantify the thermal and vibration softening effects in RV-ISF of AZ31B-H24,providing new insights into underlying thermal and vibration softening mechanism.Experimental results reveal that in RV-ISF of AZ31B-H24 the thermal softening due to frictional heating dominates with 45∼65%of softening,while the vibration effect only contributes up to 15%of softening,from the conventional ISF,depending on the tool designs and tool rotational speed.The double-offset tool(T2)produces greater vibration softening than the three-groove tool(T3)owing to the higher vibration amplitude of the T2 tool.An increase in tool rotational speed primarily enhances thermal softening with only marginal changes to the vibration effect.Microstructural analysis suggests that with average grain size of 0.94μm at the top layer,RV-ISF with T3 and 3000 rpm is more effective for microstructure refinement than that by FS-ISF,especially on the tool-sheet contact surface,which confirms the occurrence of surface shearing.This refinement is a result of the reduced recrystallisation degree,71.8%at the top bottom layer.Compared with FS-ISF,RV-ISF can lead to not only higher geometrically necessary dislocation density,but also higher fraction of low-angle grain boundaries,indicating that softening mechanism due to localised vibration effect is resulted from the enhanced rearrangement and annihilation of dislocations.These findings contribute to new understanding of the thermal and vibration softening effects in RV-ISF of AZ31B-H24 and offer a theoretical foundation for the tool design and process optimisation.展开更多
An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and h...An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and horizontal force in the process,a friction test method reflecting the forming characteristics of ISF was proposed.Friction coefficients during the forming processes of parts with different wall angles were measured under various plane curves,process paths,and lubrication conditions.Furthermore,the accuracy of the analytical model,as well as the measured friction coefficients and their variation trends,was verified through comparative analysis with experimental results,simulation data,and outcomes from other existing models.The results indicate that the influence of the plane curve characteristics and process paths of parts on the friction condition is not significant.Under the lubrication conditions of L-HM46 oil,MoS_(2)grease,graphite powder,and dry friction,the friction coefficient shows a gradually increasing trend.Notably,when the wall angle is≤40°,the friction coefficient remains relatively constant;however,when the wall angle exceeds 40°,the friction coefficient increases progressively.展开更多
In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath f...In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.展开更多
Bulge is a defect that causes geometrical inaccuracy and premature failure in the innovative incremental sheet forming (ISF) process. This study has two-fold objectives:(1) knowing the bulging behavior of a Cu clad tr...Bulge is a defect that causes geometrical inaccuracy and premature failure in the innovative incremental sheet forming (ISF) process. This study has two-fold objectives:(1) knowing the bulging behavior of a Cu clad tri-layered steel sheet as a function of forming conditions, and (2) analyzing the bending effect on bulging in an attempt to identify the associated mechanism. A series of ISF tests and bending analysis are performed to realize these objectives. From the cause-effect analysis, it is found that bulge formation in the layered sheet is sensitive to forming conditions in a way that bulging can be minimized utilizing annealed material and performing ISF with larger tool diameter and step size. The bending under tension analysis reveals that the formation of bulge is an outgrowth of bending moment that the forming tool applies on the sheet during ISF. Furthermore, the magnitude of bending moment depending upon the forming conditions varies from 0.046 to 10.24 N·m/m and causes a corresponding change in the mean bulge height from 0.07 to 0.91 mm. The bending moment governs bulging in layered sheet through a linear law. These findings lead to a conclusion that the bulge defect can be overcome by controlling the bending moment and the formula proposed can be helpful in this regards.展开更多
The double-sided incremental forming(DSIF)improved the process flexibility compared to other incremental sheet forming(ISF)processes.Despite the flexible nature,it faces the challenge of low geometric precision like I...The double-sided incremental forming(DSIF)improved the process flexibility compared to other incremental sheet forming(ISF)processes.Despite the flexible nature,it faces the challenge of low geometric precision like ISF variants.In this work,two strategies are used to overcome this.First,a novel method is employed to determine the optimal support tool location for improving geometric precision.In this method,the toolpath oriented the tools to each other systematically in the circumferential direction.Besides,it squeezed the sheet by the same amount at the point of interest.The impacts of various support tool positions in the circumferential direction are evaluated for geometric precision.The results demonstrate that the support tool should support the master tool within 10°to its local normal in the circumferential direction to improve the geometric accuracy.Second,a two-stage process reduced the geometric error of the part by incrementally accommodating the springback error by artificially increasing the step size for the second stage.With the optimal support tool position and two-stage DSIF,the geometric precision of the part has improved significantly.The proposed method is compared to the best DSIF toolpath strategies for geometric accuracy,surface roughness,forming time,and sheet thickness fluctuations using grey relational analysis(GRA).It outperforms the other toolpath strategies including single-stage DSIF,accumulative double-sided incremental forming(ADSIF),and two-stage mixed double sided incre-mental forming(MDSIF).Our approach can improve geometric precision in complex parts by successfully employing the support tool and managing the springback incrementally.展开更多
The forming principle and deformation analysis of NC incremental sheet metalforming process as well as the process planning, experiment and key process parameters of verticalwall square box forming are presented. Beca...The forming principle and deformation analysis of NC incremental sheet metalforming process as well as the process planning, experiment and key process parameters of verticalwall square box forming are presented. Because the deformation of sheet metal only occurs around thetool head and the deformed region is subjected to stretch deformation, the deformed region of sheetmetal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheetmetal deformation. The forming half-apex angle 9 and corner radius R are the main processparameters in NC incremental forming of vertical wall square box. According to sine law, a verticalwall square box can't be formed by NC incremental sheet metal forming process in a single process,rather, it must be formed in multi processes. Thus, the parallel line type tool path process methodis presented to form the vertical wall square box, and the experiment and analysis are made toverify it.展开更多
We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were use...We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were used to develop double wall angle pyramid with aid of tungsten carbide tool. GRA coupled with PCA was used to plan the experiment conditions. Control factors such as Tool Diameter(TD), Step Depth(SD), Bottom Wall Angle(BWA), Feed Rate(FR) and Spindle Speed(SS) on Top Wall Angle(TWA) and Top Wall Angle Surface Roughness(TWASR) have been studied. Wall angle increases with increasing tool diameter due to large contact area between tool and workpiece. As the step depth, feed rate and spindle speed increase,TWASR decreases with increasing tool diameter. As the step depth increasing, the hydrostatic stress is raised causing severe cracks in the deformed surface. Hence it was concluded that the proposed hybrid method was suitable for optimizing the factors and response.展开更多
The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface qu...The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.展开更多
基金the support of the Key Research and Development Program of Shaanxi Province,China(No.2021GXLH-Z-049)。
文摘The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.
文摘This study performs single point incremental forming(SPIF)on two aluminum alloys(i.e.AA5754 and AA6061),and analyzes their post forming mechanical properties and microstructure evolution.The forming parameters namely wall angle(35°-55°),feed rate(1-4 m/min),spindle rotational speed(50-1000 r/min),and lubricant(grease and hydraulic oil)are varied to probe detailed processing effects.The pre-and post-SPIF mechanical properties and microstructures are characterized by conducting tensile tests and optical microscopy,respectively.It is shown that an increase in the wall angle,feed rate and rotational speed causes microscopic variations in the alloys such that the grains of AA5754 and the second phase particles of AA6061 elongate.As a result,the ultimate tensile strength of the formed parts is increased by 10%for AA5754 and by 8%for AA6061.And,the ductility of AA5754 is decreased from 22.9%to 12%and that of AA6061 is decreased from 16%to 10.7%.Regarding the lubricant effect,it is shown that the mechanical properties remain insensitive to the type of lubricant employed.These results indicate that SPIF processing modifies the microstructure of Al alloys in a way to enhance the strength at the cost of ductility.
文摘The influence of the size of pre-cut hole of blank on the formability of cylindrical hole flanging in single point incremental forming（SPIF） was studied. The flange is produced in four stages starting from 45° to 90° and employing aluminum as the test material. It is shown that the hole size has significant effects on the stress/strain distribution on the cylindrical flange. The magnitude of hoop strains increases and the flange thickness increases as the hole size increases. Likewise, the von Mises stress reduces with the increasing of hole size. Further, there is a threshold value of hole size（i.e., 80 mm） below which severe stresses occur, which lead to sheet fracturing thus failing the successful forming of cylindrical flange. Moreover, the formability reduces as the hole size is increased above the threshold size. Finally, it is concluded that 80 mm is the threshold size of hole for maximizing the formability of aluminum sheet in incremental hole flanging.
文摘Incremental forming process is recently developed to form tubular parts.The fabrication cost and accuracy could be optimized if the effects of process parameters and the optimum values are specified.The aim of this research is using incremental forming of copper tubes to convert a circular tube into a square cross-sectional part.An experimental setup,consisting of a spherical forming punch and a fixture for clamping the tube is designed.The forming punch movement is controlled by a CNC machine.Full factorial design of experiments is carried out in order to determine the effects of process parameters including linear velocity,radial feed,and axial feed of the tool on the thinning ratio and the maximum outer diameter of the square cross-sectional parts.Results show that the radial feed has the major influence on the thinning ratio,while the axial feed plays the major role for the final profile.Increase of radial feed results in higher thinning ratio,and decrease of axial feed results in better shape conformity.Linear velocity does not have a significant effect on thinning ratio.Regression models are also given for predicting the determined responses.
基金financially supported by the National Natural Science Foundation of China (No.51305241)the Natural Science Foundation of Shandong Province (No. ZR2014JL040)the Shandong Province Taishan Scholar Construction Project Special Fund (No.tshw20130956)。
文摘The research of forming parameters on the ultrasonic vibration single-point incremental forming of magnesium alloy plastic deformation can provide a theoretical basis for the establishment of the forming parameters.According to the forming characteristics of magnesium alloy sheet,a new method of ultrasonic vibration-as sis ted single-point incremental forming was proposed.The influence of forming parameters on the plastic deformation of magnesium alloy was studied by finite element simulation and experimentation.The influence of vibration frequency,amplitude,friction coefficient,and tool head size on stress and thinning rate of magnesium alloy during ultrasonic vibration-as sis ted single-point asymptotic forming was studied.The results show that the vibration frequency of 20 kHz and forming tool radius of about 5 mm are beneficial for plastic deformation magnesium alloy in ultrasonic vibration-assisted single-point incremental forming.With vibration amplitude increasing,the maximum shear stress tends to decrease as a whole,but at the amplitude of 0.16 mm,the thinning rate is large and fracture occurs easily.With friction coefficient increasing,the maximum shear stress tends to increase,and there is a good linear relationship between the maximum thinning rate and the friction coefficient.
基金supported by National Natural Science Foundation of China(No. 50175034).
文摘Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.
文摘A method utilizing variable depth increments during incremental forming was proposed and then optimized based on numerical simulation and intelligent algorithm.Initially,a finite element method(FEM) model was set up and then experimentally verified.And the relation between depth increment and the minimum thickness tmin as well as its location was analyzed through the FEM model.Afterwards,the variation of depth increments was defined.The designed part was divided into three areas according to the main deformation mechanism,with Di(i=1,2) representing the two dividing locations.And three different values of depth increment,Δzi(i=1,2,3) were utilized for the three areas,respectively.Additionally,an orthogonal test was established to research the relation between the five process parameters(D and Δz) and tmin as well as its location.The result shows that Δz2 has the most significant influence on the thickness distribution for the corresponding area is the largest one.Finally,a single evaluating indicator,taking into account of both tmin and its location,was formatted with a linear weighted model.And the process parameters were optimized through a genetic algorithm integrated with an artificial neural network based on the evaluating index.The result shows that the proposed algorithm is satisfactory for the optimization of variable depth increment.
基金Fundamental Research Funds for the Central Universities[Grant No.NS2015055 and No.NP2020413]High-End Foreign Experts Project with Universities Directly under the Administration of Ministries and Commissions of the Central Government[Grant No.011951G19061]+1 种基金National Natural Science Foundation of China[Grant No.51105202]the Deanship of Scientific Research at King Saud University for funding this work through research group number RG-1439-027.
文摘Single point incremental forming(SPIF)is an innovative sheet forming process with a high economic pay-off.The formability in this process can be maximized by executing forming with a tool of specific small radius,regarded as threshold critical radius.Its value has been reported as 2.2 mm for 1 mm thick sheet materials.However,with a change in the forming conditions specifically in the sheet thickness and step size,the critical radius is likely to alter due to a change in the bending condition.The main aim of the present study is to undertake this point into account and develop a relatively generic condition.The study is composed of experimental and numerical investigations.The maximum wall angle(θmax)without sheet fracturing is regarded as sheet formability.A number of sheet materials are formed to fracture and the trends correlating formability with normalized radius(i.e.,R/To where R is the tool-radius and To is the sheet thickness)are drawn.These trends confirm that there is a critical tool-radius(Rc)that maximizes the formability in SPIF.Furthermore,it is found that the critical radius is not fixed rather it shows dependence on the sheet thickness such that Rc=βTo,whereβvaries from 2.2 to 3.3 as the thickness increases from 1 mm to 3 mm.The critical radius,however,remains insensitive to variation in step size ranging from 0.3 mm to 0.7 mm.This is also observed that the selection of tool with R<Rc narrows down the formability window not only on the higher side but also on the lower side.The higher limit,as revealed by the experimental and FEA results,diminishes due to excessive shearing because of in-plane biaxial compression,and the lower limit reduces due to pillowing in the bottom of part.The new tool-radius condition proposed herein study would be helpful in maximizing the formability of materials in SPIF without performing experimental trials.
基金Project(51005258) supported by the National Natural Science Foundation of ChinaProject(CDJZR12130065) supported by the Fundamental Research Funds for the Central Universities,China
文摘Although multi-stage incremental sheet forming has always been adopted instead of single-stage forming to form parts with a steep wall angle or to achieve a high forming performance, it is largely dependent on empirical designs. In order to research multi-stage forming further, the effect of forming stages(n) and angle interval between the two adjacent stages(Δα) on thickness distribution was investigated. Firstly, a finite element method(FEM) model of multi-stage incremental forming was established and experimentally verified. Then, based on the proposed simulation model, different strategies were adopted to form a frustum of cone with wall angle of 30° to research the thickness distribution of multi-pass forming. It is proved that the minimum thickness increases largely and the variance of sheet thickness decreases significantly as the value of n grows. Further, with the increase of Δα, the minimum thickness increases initially and then decreases, and the optimal thickness distribution is achieved with Δα of 10°.Additionally, a formula is deduced to estimate the sheet thickness after multi-stage forming and proved to be effective. And the simulation results fit well with the experimental results.
基金Funded by the National Natural Science Foundation of China(Nos.51245010 and 51405242)the Natural Science Foundation of Jiangsu Province,China(No.BK2012463)
文摘To solve the problems of poor forming and easy adhesion of the stainless steel,Cu alloyed layer on the stainless steels was prepared by the double glow plasma surface alloying technique.The experimentalresults indicated that the supersaturated copper dispersedly precipitated in grain interior and crystalboundaries and formed the vermicular structure.The tribologicaltests indicated that the friction coefficient of the Cu alloyed layer was lower than that of the stainless steels.The wear rate of stainless steelin the presence of Cu alloyed layer was approximately 2-fold lower than that in the absence of the alloyed layer.The results of the incrementalforming indicated that the ploughing phenomenon was not observed on the stainless steelin the presence of Cu alloyed layer during the incrementalforming,while the stainless steelpresented the deep ploughing.Therefore,Cu alloyed layer on stainless steelexhibited excellent self-lubrication and forming properties.
基金National Natural Science Foundation of China(No.51205217)
文摘By friction heating single point incremental forming,truncated square pyramid parts with different draw angles of a magnesium alloy AZ31 B were formed at room temperature.Metallurgical,tensile and micro-hardness tests were carried out to obtain the effects of wall angle on microstructure and mechanical properties. The results show that grain in side wall of the formed parts becomes refined significantly. Furthermore,with the increase of draw angle,grain size increases,but strength,hardness and plasticity decrease. In addition, surface roughness tests were performed on the formed surface to determine the influence of speed of forming tool. The results show that surface roughness has a little increase with the increase of tool rotational speed.
文摘Sheet metal single point incremental forming （SPIF） is a new technology for flexible process. The springback phenomenon in single point incremental forming has been discussed. Effects of forming angle and shape of the part are analysed using simple experimental method. Tool diameter, sheet thickness, step size, material parameters and the interaction of them are also analysed by using orthogonal test. The results show that the primary factor af- fecting springback is forming angle. In addition, springback is decreased when the specimen has a larger forming angle. The order of the four factors that influence springback is tool diameter, sheet thickness, step size and material parameters. The forming precision will increase if springabck is decreased by optimizing the forming parameters.
基金the financial support received from the UK Engineering and Physical Sciences Research Council(EPSRC)through project grants EP/W010089/1 and EP/T005254/1.
文摘With the generation of both localised thermal and vibration in incremental sheet forming(ISF)by novel tool designs,rotational vibration assisted ISF(RV-ISF)can achieve significant force reduction and material softening.However,the combined thermal and vibration softening in RV-ISF is unclear.By evaluating the similarities and differences of friction stir ISF(FS-ISF)and RV-ISF,this study develops a novel approach to decouple and quantify the thermal and vibration softening effects in RV-ISF of AZ31B-H24,providing new insights into underlying thermal and vibration softening mechanism.Experimental results reveal that in RV-ISF of AZ31B-H24 the thermal softening due to frictional heating dominates with 45∼65%of softening,while the vibration effect only contributes up to 15%of softening,from the conventional ISF,depending on the tool designs and tool rotational speed.The double-offset tool(T2)produces greater vibration softening than the three-groove tool(T3)owing to the higher vibration amplitude of the T2 tool.An increase in tool rotational speed primarily enhances thermal softening with only marginal changes to the vibration effect.Microstructural analysis suggests that with average grain size of 0.94μm at the top layer,RV-ISF with T3 and 3000 rpm is more effective for microstructure refinement than that by FS-ISF,especially on the tool-sheet contact surface,which confirms the occurrence of surface shearing.This refinement is a result of the reduced recrystallisation degree,71.8%at the top bottom layer.Compared with FS-ISF,RV-ISF can lead to not only higher geometrically necessary dislocation density,but also higher fraction of low-angle grain boundaries,indicating that softening mechanism due to localised vibration effect is resulted from the enhanced rearrangement and annihilation of dislocations.These findings contribute to new understanding of the thermal and vibration softening effects in RV-ISF of AZ31B-H24 and offer a theoretical foundation for the tool design and process optimisation.
基金the National Key R&D Program of China(No.2023YFB3407003)the National Natural Science Foundation of China(No.52375378).
文摘An analytical model for contact area and contact stress considering the loading history in incremental sheet forming(ISF)was established.Then,by integrating with the directional characteristics of friction force and horizontal force in the process,a friction test method reflecting the forming characteristics of ISF was proposed.Friction coefficients during the forming processes of parts with different wall angles were measured under various plane curves,process paths,and lubrication conditions.Furthermore,the accuracy of the analytical model,as well as the measured friction coefficients and their variation trends,was verified through comparative analysis with experimental results,simulation data,and outcomes from other existing models.The results indicate that the influence of the plane curve characteristics and process paths of parts on the friction condition is not significant.Under the lubrication conditions of L-HM46 oil,MoS_(2)grease,graphite powder,and dry friction,the friction coefficient shows a gradually increasing trend.Notably,when the wall angle is≤40°,the friction coefficient remains relatively constant;however,when the wall angle exceeds 40°,the friction coefficient increases progressively.
基金Project(50175034) supported by the National Natural Science Foundation of China
文摘In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.
基金the financial help and technical support that King Abdulaziz University provided for this research work
文摘Bulge is a defect that causes geometrical inaccuracy and premature failure in the innovative incremental sheet forming (ISF) process. This study has two-fold objectives:(1) knowing the bulging behavior of a Cu clad tri-layered steel sheet as a function of forming conditions, and (2) analyzing the bending effect on bulging in an attempt to identify the associated mechanism. A series of ISF tests and bending analysis are performed to realize these objectives. From the cause-effect analysis, it is found that bulge formation in the layered sheet is sensitive to forming conditions in a way that bulging can be minimized utilizing annealed material and performing ISF with larger tool diameter and step size. The bending under tension analysis reveals that the formation of bulge is an outgrowth of bending moment that the forming tool applies on the sheet during ISF. Furthermore, the magnitude of bending moment depending upon the forming conditions varies from 0.046 to 10.24 N·m/m and causes a corresponding change in the mean bulge height from 0.07 to 0.91 mm. The bending moment governs bulging in layered sheet through a linear law. These findings lead to a conclusion that the bulge defect can be overcome by controlling the bending moment and the formula proposed can be helpful in this regards.
基金supported by the National Natural Science Foun-dation of China(Nos.52075025,51975328)Project funded by China Postdoctoral Science Foundation(No.2021T140418)。
文摘The double-sided incremental forming(DSIF)improved the process flexibility compared to other incremental sheet forming(ISF)processes.Despite the flexible nature,it faces the challenge of low geometric precision like ISF variants.In this work,two strategies are used to overcome this.First,a novel method is employed to determine the optimal support tool location for improving geometric precision.In this method,the toolpath oriented the tools to each other systematically in the circumferential direction.Besides,it squeezed the sheet by the same amount at the point of interest.The impacts of various support tool positions in the circumferential direction are evaluated for geometric precision.The results demonstrate that the support tool should support the master tool within 10°to its local normal in the circumferential direction to improve the geometric accuracy.Second,a two-stage process reduced the geometric error of the part by incrementally accommodating the springback error by artificially increasing the step size for the second stage.With the optimal support tool position and two-stage DSIF,the geometric precision of the part has improved significantly.The proposed method is compared to the best DSIF toolpath strategies for geometric accuracy,surface roughness,forming time,and sheet thickness fluctuations using grey relational analysis(GRA).It outperforms the other toolpath strategies including single-stage DSIF,accumulative double-sided incremental forming(ADSIF),and two-stage mixed double sided incre-mental forming(MDSIF).Our approach can improve geometric precision in complex parts by successfully employing the support tool and managing the springback incrementally.
基金This project is supported by National Natural Science Foundation of China (No.50175034).
文摘The forming principle and deformation analysis of NC incremental sheet metalforming process as well as the process planning, experiment and key process parameters of verticalwall square box forming are presented. Because the deformation of sheet metal only occurs around thetool head and the deformed region is subjected to stretch deformation, the deformed region of sheetmetal thins, and surface area increases. Sheet metal forming stepwise is to lead to the whole sheetmetal deformation. The forming half-apex angle 9 and corner radius R are the main processparameters in NC incremental forming of vertical wall square box. According to sine law, a verticalwall square box can't be formed by NC incremental sheet metal forming process in a single process,rather, it must be formed in multi processes. Thus, the parallel line type tool path process methodis presented to form the vertical wall square box, and the experiment and analysis are made toverify it.
文摘We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were used to develop double wall angle pyramid with aid of tungsten carbide tool. GRA coupled with PCA was used to plan the experiment conditions. Control factors such as Tool Diameter(TD), Step Depth(SD), Bottom Wall Angle(BWA), Feed Rate(FR) and Spindle Speed(SS) on Top Wall Angle(TWA) and Top Wall Angle Surface Roughness(TWASR) have been studied. Wall angle increases with increasing tool diameter due to large contact area between tool and workpiece. As the step depth, feed rate and spindle speed increase,TWASR decreases with increasing tool diameter. As the step depth increasing, the hydrostatic stress is raised causing severe cracks in the deformed surface. Hence it was concluded that the proposed hybrid method was suitable for optimizing the factors and response.
基金support from the National Natural Science Foundation of China(51575028)National Natural Science Foundation of China(51605258)the Fundamental Research Funds for the Central Universities of China(YWF-18-BJ-J-75)。
文摘The unsatisfied surface quality seriously impedes the wide application of incremental sheet forming(ISF)in industrial field.As a novel approach,the interpolator method is a promising strategy to enhance the surface quality in ISF.However,the mechanism for the improvement of surface quality and the influence of interpolator properties on surface roughness are not well understood.In this paper,the influences of process variables(i.e.tool diameter,step size and thickness of interpolators)on the forming process(e.g.surface roughness,forming force and geometric error)are investigated through a systematic experimental approach of central composite design(CCD)in two-point incremental sheet forming(TPIF).It is obtained that the increase in thickness of interpolators decreases the surface roughness in direction vertical to the tool path while increases the surface roughness in direction horizontal to the tool path.Nevertheless,the combined influence between thickness of interpolators and process parameters(tool diameter and step size)is limited.Meanwhile,the placement of interpolator has little influence on the effective forming force of blank.In addition,the geometric error enlarges with the increase of step size and thickness of interpolator while decreases firstly and then increase with an increase in tool diameter.Finally,the influencing mechanism of the interpolator method on surface quality can be attributed to the decrease of thecontact pressure due to the increase of contact area with the unchanged contact force.Meanwhile,the interpolator method eliminates the sliding friction on the surface of blank due to the stable relative position between the blank and the interpolator.
