Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Abstract
The idea of incremental forming technique has been investigated for production of sheet metal components. With this technique, the
forming limit curve (FLC) appears in a different pattern, revealing an enhanced formability, compared to conventional forming techniques.
In the present study, the formability of an aluminum sheet under various forming conditions was assessed and difficult-to-form shapes
were produced with the technique. By utilizing knowledge and experience obtained during the present study, it became possible to produce
some free surfaces.
2003 Elsevier B.V. All rights reserved.
Keywords: Incremental forming; Formability; Forming limit curve; Sheet metal; Aluminum
1. Introduction
0924-0136/$ see front matter 2003 Elsevier B.V. All rights reserved.
doi:10.1016/S0924-0136(03)00768-4
448
J.-J. Park, Y.-H. Kim / Journal of Materials Processing Technology 140 (2003) 447453
Fig. 3. Forming of rectangular cones: (a) by negative forming, (b) by positive forming, (c) jig for positive forming, and (d) strain distributions of both
methods.
J.-J. Park, Y.-H. Kim / Journal of Materials Processing Technology 140 (2003) 447453
449
Fig. 4. Forming of octagonal cones: (a) with flat surface, (b) with convex surface, (c) with concave surface, and (d) strain distributions with FLCs.
450
J.-J. Park, Y.-H. Kim / Journal of Materials Processing Technology 140 (2003) 447453
Fig. 5. Forming of a bucket shape: (a) formed shape, (b) support tool, and (c) strain distributions with FLCs.
J.-J. Park, Y.-H. Kim / Journal of Materials Processing Technology 140 (2003) 447453
451
Fig. 6. Forming of a stepped shape: (a) formed shape, (b) support tool, (c) strain distributions with FLCs, (d) FEM simulation of stretching, and (e)
FEM simulation of deep drawing.
carefully prepared as the shape became complicated. Otherwise, the formed shape would not match well with a desired
shape.
A disk shape shown in Fig. 7(a) was formed with the
jig in which the support column was replaced with the pattern in Fig. 7(b). In the process of forming, a sheet was
located on the pattern and the tool moved along circular
paths with appropriate vertical movements. Stretching process of the shape was simulated by PAM-STAMP, as shown
in Fig. 7(c). It was found that the maximum of the major strain reached 0.22. Strain distributions were measured
as well as obtained from the simulation, as presented in
Fig. 7(d). The strains from the incremental forming are all
around the plane-strain stretching mode while those from the
stretching process are distributed from the plane-stretching
mode to the biaxial stretching mode. They are all below the
FLCs. However, it is expected that cracks would take place in
the stretching process as the shape of the disk becomes more
complicated.
452
J.-J. Park, Y.-H. Kim / Journal of Materials Processing Technology 140 (2003) 447453
Fig. 7. Forming of a complex disk: (a) formed shape, (b) support tool (or pattern), (c) FEM simulation of stretching, and (d) strain distributions with FLCs.
4. Conclusion
Fundamental investigations of the incremental sheet metal
forming technique were performed in the present study.
Also, conventional techniques such as stretching and deep
drawing processes were simulated by a commercial FEM
package for the purpose of comparison in the aspect of forming capabilities. The result of the present study can be summarized as follows:
(1) The incremental forming technique, especially with
the positive forming method, is better than conventional ones. The forming capability increases as the
plane-strain mode of deformation is more introduced.
(2) With the negative forming method, it is difficult to form
sharp corners or edges because cracks easily occur due
to the biaxial mode of deformation.
(3) With the positive forming method, it is possible to form
complicated shapes with sharp corners or edges because
the plane-strain mode of deformation becomes quite
dominant.
(4) In the positive forming method, the support column of
the jig should be properly designed, depending upon
complexity of the shape to be formed.
Acknowledgements
The present study was supported by 2003 Hong-Ik University Research Fund.
References
[1] H. Iseki, H. Kumon, Forming limit of incremental sheet metal stretch
forming using spherical rollers, J. JSTP 35 (1994) 1336.
[2] S. Matsubara, Incremental backward bulge forming of a sheet metal
with a hemispherical head tool, J. JSTP 35 (1994) 1311.
[3] K. Dai, Z.R. Wang, Y. Fang, CNC incremental sheet forming of
axially symmetric specimen and the locus of optimization, J. Mater.
Process. Technol. 102 (2000) 164.
[4] H. Iseki, An approximate deformation analysis and FEM analysis for
the incremental bulging of sheet metal using a spherical roller, J.
Mater. Process. Technol. 111 (2001) 150.
[5] H. Iseki, T. Naganawa, Vertical wall surface forming of rectangular
shell using multistage incremental forming with spherical and cylindrical rollers, J. Mater. Process. Technol. 130 (2002) 657.
J.-J. Park, Y.-H. Kim / Journal of Materials Processing Technology 140 (2003) 447453
[6] M.S. Shim, J.-J. Park, The formability of aluminum sheet in
incremental forming, J. Mater. Process. Technol. 113 (2001)
654.
[7] Y.-H. Kim, J.-J. Park, Effect of parameters on formability in incremental forming of sheet metal, J. Mater. Process. Technol. 130 (2002)
42.
453