Mechanics based Integrated Product and Process Design for Incremental Forming

Lingam, R and Bansal, Ankush and I, Om Prakash and Reddy, N Venkata (2017) Mechanics based Integrated Product and Process Design for Incremental Forming. Journal of Manufacturing Science and Engineering. ISSN 1087-1357

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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.

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