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Design Innovation Paper

A Novel Electromagnetic Fixture for Incremental Sheet Metal Forming

[+] Author and Article Information
Harish K. Nirala

Department of Mechanical Engineering,
Indian Institute of Technology Ropar,
Rupnagar 140001, Punjab, India
e-mail: harish.nirala@iitrpr.ac.in

Anupam Agrawal

Department of Mechanical Engineering,
Indian Institute of Technology Ropar,
Rupnagar 140001, Punjab, India
e-mail: anupam@iitrpr.ac.in

1Corresponding author.

Manuscript received April 30, 2018; final manuscript received November 21, 2018; published online February 15, 2019. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 141(3), 035001 (Feb 15, 2019) (10 pages) Paper No: MANU-18-1280; doi: 10.1115/1.4042109 History: Received April 30, 2018; Revised November 21, 2018

Single-point incremental sheet forming (SPISF) is a promising die-less forming technique. It has a variety of applications in many industries, viz., automobile, aerospace, and bone transplants. In SPISF, a sheet of metal is deformed by using numerically controlled single-point, hemispherical end-shaped forming tool, which incrementally deforms the sheet with highly localized plastic deformation. SPISF is a flexible yet relatively slow process when compared with conventional forming techniques like deep drawing and spinning. Since the beginning of die-less forming technology, researchers are recommending it for small batch production system or for customized fabrication. Being a slow process, it still has not achieved wide industrial acceptability. Among several key parameters dictating the process speed, the sheet clamping mechanism is one of the significant parameters of SPISF. Clamping mechanism plays a vital role in its manufacturing lead time. However, research efforts in this direction have been largely neglected. In this investigation, to improve the process speed, a novel electromagnetic clamping mechanism for SPISF is proposed. Detailed numerical and experimental investigations have been carried out to set up its applicability for the SPISF process. From the available literature, it has been found that this type of clamping mechanism in SPISF has not been studied or investigated. The proposed electromagnetic clamping makes the process of sheet clamping faster and convenient, and provides one-click clamping solution. This concept can take the process of incremental sheet forming toward better industrial acceptability. Furthermore, SPISF of symmetric and asymmetric components is conducted to test the feasibility of the concept.

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Figures

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Fig. 4

(a) Primary setup for EF and (b) machine setup for EF

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Fig. 3

(a) Computer-aided design (CAD) model for D-shell and (b) fabricated D-shell by ISF at IIT Ropar

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Fig. 2

Some applications of ISF: (a) Cranial bone reconstruction [7] (Reprinted from permission of Springer Nature © 2008), (b) Deep conical geometry [8] (Reprinted from permission of Springer Nature © 2008), (c) Petal surface fabricated by ISF at IIT Ropar, (d) Circular generatrix profile fabricated at IIT Ropar [7,8]

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Fig. 1

Schematic representation of SPISF process

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Fig. 6

Assembled setup for numerical investigation of SPISF process

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Fig. 5

Conventional fixture: (a) CAD model and (b) fabricated fixture

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Fig. 7

Incremental toolpath in matlab for (a) D-shell and (b) frustum of a square pyramid

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Fig. 8

Numerical simulation results: (a) D-shell, (b) frustum of square pyramid, and (c) wall angle prediction for square pyramid

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Fig. 9

Frustum of a square pyramid by ISF using (a) conventional fixture and (b) EF

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Fig. 10

D-Shell by ISF using (a) conventional fixture and (b) EF

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Fig. 11

Forming force comparison: D-shell by ISF using conventional and EF

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Fig. 12

Forming force comparison: frustum of a square pyramid by ISF using conventional and EF

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