Analysis of Pre-Strain in a Hybrid Forming Process Including Stretch and Incremental Sheet 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.Keywords:
Incremental sheet forming
Deep drawing
Strain (injury)
Roll forming
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
Strain (injury)
Multi point
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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 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.
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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.
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Incremental sheet metal forming (ISMF) is a dieless sheet forming process that has emerged over the last decade as an economic alternative for rapid manufacturing and small batch production. It has become one of the leading R&D topics in the industry. It was reported that the incremental sheet metal forming produces larger deformations as compared to the conventional forming processes. In this study, a theoretical method based on M–K analysis is presented to determine the forming limit curve (FLC) in this process. A case study is also given to demonstrate the proposed method.
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Roll forming
Forming limit diagram
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