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Research Papers: FORMING

Effects of Tool Positions in Accumulated Double-Sided Incremental Forming on Part Geometry

[+] Author and Article Information
Huaqing Ren

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: huaqingren2013@u.northwestern.edu

Newell Moser

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: NewellMoser2018@u.northwestern.edu

Zixuan Zhang

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: ZixuanZhang2018@u.northwestern.edu

Ebot Ndip-Agbor

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: ebotndipagbor2012@u.northwestern.edu

Jacob Smith

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: jacobsmith2011@u.northwestern.edu

Kornel F. Ehmann

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: k-ehmann@northwestern.edu

Jian Cao

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208
e-mail: jcao@northwestern.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received December 22, 2014; final manuscript received April 28, 2015; published online September 4, 2015. Assoc. Editor: Jingjing Li.

J. Manuf. Sci. Eng 137(5), 051008 (Sep 04, 2015) (8 pages) Paper No: MANU-14-1703; doi: 10.1115/1.4030528 History: Received December 22, 2014

In accumulated double-sided incremental forming (ADSIF), two hemispherical tools impart the local deformation to the sheet via their programed in-plane spiral motion and the depth of the part is achieved via rigid body motion of the already formed part. Unlike single point incremental forming (SPIF) and double-sided incremental forming (DSIF), ADSIF does not impose forces on the already-formed part and, therefore, has the potential of achieving higher geometric accuracy. A systematic method is proposed in this work to study the influences of the relative tool positions on the local formed shape and the final geometry, which is essentially the accumulation of all previously formed local deformations. Meanwhile, the concepts of the stable angle and the peak angle are introduced to better describe the cross-sectional geometry of a formed part with a constant wall angle at that particular cross section. It is recommended that, while multiple combinations of the relative positions of two forming tools may achieve the same stable angle that the positioning parameters should be chosen such that the resultant forming force or the wall angle variation between the stable and peak angles is minimized.

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References

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Figures

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Fig. 1

Difference in (a) DSIF and (b) ADSIF toolpath

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Fig. 2

Typical forming force histories in ADSIF

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Fig. 3

Top tool tip points in ADSIF for a single cone without fillets

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Fig. 4

Schematic of toolpath parameters

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Fig. 6

Cross section comparison between the simulation and the experiment

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Fig. 7

Design space and applicable simulation results

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Fig. 8

Wall angle plot along radius

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Fig. 9

Simulation results of different tool positions

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Fig. 10

Mesh surface for the stable angle

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Fig. 11

Wall angle profiles of different T¯g and θ

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Fig. 12

Mesh surface of angle variation

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Fig. 13

ADSIF deformation process

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Fig. 14

Representative thickness change at one radial location (r = 21 mm) as a result of different T¯g and θ

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Fig. 15

Mesh surface for horizontal forming force of (a) forming tool, (b) supporting tool

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Fig. 16

Experiments results (a) cross section and (b) angle variation in cross section

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Fig. 17

Horizontal forming forces in experiments

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