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research-article

Mechanics based Integrated Product and Process Design for Incremental Forming

[+] Author and Article Information
Rakesh Lingam

Department of Mechanical and Aerospace Engineering, Indian Institute of Technology Hyderabad, Kandi, Telangana 502 285, India
me13p1009@iith.ac.in

Ankush Bansal

Department of Mechanical and Aerospace Engineering, Indian Institute of Technology Hyderabad, Kandi, Telangana 502 285, India
me11b007@iith.ac.in

I Om Prakash

Boeing Research and Technology-India Centre, 3rd Floor, Block B, RMZ Infinity, Old Madras Road, Bengaluru 560 016, India
om.prakash2@boeing.com

N. Venkata Reddy

Department of Mechanical and Aerospace Engineering, Indian Institute of Technology Hyderabad, Kandi, Telangana 502 285, India
nvr@iith.ac.in

1Corresponding author.

ASME doi:10.1115/1.4038600 History: Received May 01, 2017; Revised August 22, 2017

Abstract

Incremental sheet forming (ISF) is a low cost, die-less forming process suitable for low volume production. In case of components with multiple features, the accuracy of formed component depends on the sequence in which the features are formed. In addition, sheet spring-back, tool deflection and rigid body displacement also effect the accuracy of the component. Predicting the component geometry using finite element analysis is computationally expensive and time consuming. Simple mechanics based methodology is presented in this work to predict the component geometry. Results presented show that the formed component geometry can be predicted with good accuracy. In addition a methodology is developed to achieve uniform thickness distribution with good accuracy in high wall angle components formed using multi-stage strategy. This thickness prediction capability helps the designer to choose intermediate stages and to form components with engineered thickness with reasonable accuracy.

Copyright (c) 2017 by ASME
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