Upper Bound Analysis of Single Point Incremental Forming

Sahu, C (2014) Upper Bound Analysis of Single Point Incremental Forming. Masters thesis, Indian Institute of Technology Hyderabad.

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Abstract

Most of the conventional sheet metal forming processes uses expensive dies for forming sheet metals into final shape. This increases the cost of production. For eliminating these limitation one can utilize the new die less sheet metal forming process known as incremental sheet metal forming (ISMF). The process involves the use of a single spherical tool to carry out local sheet metal deformation progressively on a CNC milling machine. The controlled movement of the tool enables a 3-dimensional profile to be made. The process can provide rapid prototyping advantages for sheet metal parts which are made directly from a 3-D CAD model to finished product without the conventional intermediate stage of tool design and manufacture. In this report the methodology of the Single Point Incremental Forming (SPIF) and Double Sided Incremental Forming (DSIF) processes are presented. Initially the CAD model of the final shape is produced then the STEP file is used to create tool path for the ISMF process by using tool path generating module. This tool path is then given as an input to the CNC machine and the desired motion of tool is obtained in order to produce the final shape. First the FEM analysis of Single Point Incremental Forming (SPIF) is done in order to analyze the deformation zone and the velocity fields. Then upper bound approach is used to study the deformation zone of SPIF. The velocity field and power dissipated are predicted using assumed deformation zone. The incremental sheet metal forming has a potential application in field of aerospace and biomedical industries which are constantly looking for ways to reduce the weight and to improve the mechanical properties of parts and structures. The major advantage of ISMF technology is the possibility to manufacture sheet parts which are difficult to form with traditional processes in a rapid and economic way without expensive dies and long set-up times.

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