Research Papers

Basic Analysis of the Incremental Profile Forming Process

[+] Author and Article Information
Goran Grzancic

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Straße 303,
Dortmund 44227, Germany
e-mail: Goran.Grzancic@iul.tu-dortmund.de

Christoph Becker

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Straße 303,
Dortmund 44227, Germany
e-mail: Christoph.Becker@iul.tu-dortmund.de

Nooman Ben Khalifa

Institute of Forming Technology
and Lightweight Construction,
TU Dortmund University,
Baroper Straße 303,
Dortmund 44227, Germany
e-mail: Nooman.Ben_Khalifa@iul.tu-dortmund.de

1Corresponding author.

Manuscript received October 9, 2015; final manuscript received April 26, 2016; published online June 20, 2016. Assoc. Editor: Rajiv Malhotra.

J. Manuf. Sci. Eng 138(9), 091002 (Jun 20, 2016) (6 pages) Paper No: MANU-15-1510; doi: 10.1115/1.4033521 History: Received October 09, 2015; Revised April 26, 2016

Increasing demands in profile manufacturing leads to a constant increase of the geometric complexity of the profile. Nowadays, lightweight design and load adaption are of huge importance and a need for new profile manufacturing technologies exists. In order to cope with this development, a new tube profile forming method was invented, the incremental profile forming (IPF). IPF allows the flexible manufacturing of profiles with varying cross section geometries along the longitudinal profile axis and offers therefore a high potential for the manufacturing of lightweight design parts. Due to the high degree of innovation, research work regarding the process fundamentals as well as the process limits is necessary. For this reason, the results of the first basic experimental and numerical investigations are presented. While in the experiments, the potential of the process is shown in feasibility studies, first analyses of the forming process, and the influence of different process parameters on the process were carried out in numerical investigations. In particular, it turned out that the tool infeed and tube dimensions have significant influence on the forming force, whereas the tool radius has a minor influence.

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Fig. 8

Finite element (FE)-model setup

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Fig. 7

Forming zone (a) experimental (forming zone after indentation) (b) schematic (radial infeed (section 1) and axial feed (section 2))

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Fig. 6

Characteristic force evolution in simplified IPF

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Fig. 5

Experimental setup of simplified IPF

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Fig. 4

(a) Process parameters (b) tool path and groove geometry

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Fig. 3

Experimental machine setup

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Fig. 2

Manufactured parts

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Fig. 1

Process principle for IPF

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Fig. 10

Maximal tube end displacements at different tube lengths

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Fig. 11

Model verification—force evolution

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Fig. 12

Model verification—geometric deviation analysis

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Fig. 9

Flow curve—approximation by Swift equation

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Fig. 13

Influence of tool infeed and tool radius on forming force

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Fig. 14

Influence of tube dimensions

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Fig. 15

Bending deformation



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