A wide-panel forming process to replace conventional roll forming
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Incremental sheet forming
The unique process of sheet-bulk metal forming (SBMF) represents a combination of sheet and bulk metal forming by inducing a three-dimensional material flow in sheet metals in a single forming stage. Within this paper two different applications of sheet-bulk metal forming are demonstrated. Hereby two different combined drawing and upsetting processes to realize parts with symmetrically and asymmetrically arranged functional elements are analysed. Finally, this contribution introduces a new machine technique which provides an improvement of the working accuracy of a forming machine and thus has a positive influence on the parts quality. The idea is to use electromagnetic ram guidance to counteract the displacement of the ram due to horizontal forming forces while forming of asymmetric parts.
Electromagnetic forming
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The conventional sheet metal forming processes, such as deep drawing and stretch forming, are used to produce large batches of parts, however they incur in higher initial manufacturing costs attributed to the use of a large amount of tooling. The application of conventional and incremental forming processes combined in the same metal sheet is called hybrid forming. This hybrid process is enacted by pre-forming the sheet through the stretch forming process followed by the final manufacture using the incremental process. The objective of this work is to analyze the influence of the pre-strain imposed during the conventional process on the DC04 steel relative to the maximum strain obtained. A numerical simulation was used to define the parameters for the conventional process and to evaluate the experimental results. The higher major true strains are inversely proportional to the pre-strain in both experimental and simulated results.
Incremental sheet forming
Deep drawing
Strain (injury)
Roll forming
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NC incremental sheet metal forming process is a flexible process which is to form the sheet point by point on NC forming machine according to the prepared program .The forming principle of NC incremental sheet metal forming process is presented. The strain is analysed. A formula of strain calculation is drawn in the NC incremental sheet metal forming process and verified by web experiment.
Incremental sheet forming
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Multi point
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Roll forming
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Incremental sheet forming
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Incremental sheet forming
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NC incremental sheet parts forming process is a flexible process which is to form the sheet point by point on NC forming machine according to the prepared program .In this paper, the forming principle of NC incremental sheet metal parts forming process , the ultimate half-apex angle are presented, and so on . Sheet thickness is thinned, surface area is increased in the NC incremental sheet metal parts forming process , and sheet forming point by point is to lead to the whole sheet deformation.The thickness varies according to the half-apex angle, and the forming limit half-apex angle is the key which NC incremental sheet metal parts forming process succeeds, it relates to the material and thickness of the sheet metal.
Incremental sheet forming
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Incremental sheet forming
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The CNC incremental sheet metal forming process is a flexible forming process without dedicated forming dies.In process planning,the forming trace of the forming tool can be adjusted by correcting the numerical model of the product.Sheet metal incremental forming of the auto chair is more difficult.In this paper,the CNC incremental sheet metal forming process is analyzed.Based on the above research,the method of processing design(including model building,processing analysis,trajectory creating,HrpDSF proceeding,post proceeding,etc.) has been established.The success incremental forming of the auto chair using the processing design method has provided.The defects occurred in the incremental forming of the auto chair,such as fracture,wrinkle and spring back degrade the quantity of the production.This paper discusses these defects and supposes suitable method to avoid the defects.This is helpful to the development of the sheet metal incremental forming in the future.
Incremental sheet forming
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Incremental sheet metal forming is an evolving process, which is suitable for the production of limited quantities of sheet metal components. The main advantages of this process over conventional forming processes are reduced setup cost and manufacturing lead time, as it eliminates the need of special purpose dies, improves formability, reduces forming forces, and provides process flexibility. The objective of this work is to investigate a new hybrid-forming process, which intends to combine incremental sheet metal forming with deep drawing process and has been named as “incremental stretch drawing.” A number of setups and fixtures were developed to carry out experiments to achieve incremental stretch drawing and understand the mechanism of the process. This process addresses some of the challenges of incremental sheet metal forming, that is, limited formability in terms of forming depth, especially at steeper wall angles and subsequent thinning of sheet. It is observed that the proposed process is able to reduce thinning as much as about 300%, considering same forming depth for incremental sheet metal forming and incremental stretch drawing processes. Improvement in formability, in terms of forming depths, also has been observed to be near about 100% in particular cases.
Incremental sheet forming
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Deep drawing
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