Analytical prediction of stepped feature generation in multi-pass single point incremental forming

Dong Kai Xu*, Rajiv Malhotra, Jian Cao, N. V. Reddy, Jun Chen

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Single Point Incremental Forming (SPIF) is a new sheet metal forming process characterized by higher formability, product independent tooling and greater process flexibility. The inability of conventional single pass SPIF to form vertical walls without failure is overcome by forming multiple intermediate shapes before forming the final component, i.e., Multi-pass Single Point Incremental Forming (MSPIF). A major issue with MSPIF is significant geometric inaccuracy of the formed component, due to generation of stepped features on the base. This work proposes analytical formulations that are shown to accurately and quantitatively predict stepped feature formation in MSPIF. Additionally, a relationship is derived between the material constants used in these analytical equations and the yield stress and thickness of the blank material, so that computational effort required for calibration of these constants can be minimized. Finally, the physical effects of the yield stress and the sheet thickness on the rigid body translation are further discussed.

Original languageEnglish (US)
Title of host publication40th North American Manufacturing Research Conference 2012 - Transactions of the North American Manufacturing Research Institution of SME
Pages84-93
Number of pages10
StatePublished - Nov 28 2012
Event40th Annual North American Manufacturing Research Conference, NAMRC40 - Notre Dame, IN, United States
Duration: Jun 4 2012Jun 8 2012

Publication series

NameTransactions of the North American Manufacturing Research Institution of SME
Volume40
ISSN (Print)1047-3025

Other

Other40th Annual North American Manufacturing Research Conference, NAMRC40
CountryUnited States
CityNotre Dame, IN
Period6/4/126/8/12

Keywords

  • Material constant prediction
  • Multi-pass single point incremental forming (MSPIF)
  • Rigid body translation

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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  • Cite this

    Xu, D. K., Malhotra, R., Cao, J., Reddy, N. V., & Chen, J. (2012). Analytical prediction of stepped feature generation in multi-pass single point incremental forming. In 40th North American Manufacturing Research Conference 2012 - Transactions of the North American Manufacturing Research Institution of SME (pp. 84-93). (Transactions of the North American Manufacturing Research Institution of SME; Vol. 40).