Improvement of geometric accuracy in incremental forming by using a squeezing toolpath strategy with two forming tools

Rajiv Malhotra*, Jian Cao, Feng Ren, Vijitha Kiridena, Z. Cedric Xia, N. V. Reddy

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

77 Scopus citations

Abstract

Single point incremental forming (SPIF) is plagued by an unavoidable and unintended bending in the region of the sheet between the current tool position and the fixture. The effect is a deformation of the region of the sheet in between the formed area and the fixture as well as deformation of the already formed portion of the wall, leading to significant geometric inaccuracy in SPIF. Double sided incremental forming (DSIF) uses two tools, one on each side of the sheet to form the sheet into the desired shape. This work explores the capabilities of DSIF in terms of improving the geometric accuracy as compared to SPIF by using a novel toolpath strategy in which the sheet is locally squeezed between the two tools. Experiments and simulations are performed to show that this strategy can improve the geometric accuracy of the component significantly by causing the deformation to be stabilized into a local region around the contact point of the forming tool. At the same time an examination of the forming forces indicates that after a certain amount of deformation by using this strategy a loss of contact occurs between the bottom tool and the sheet. The effects of this loss of contact of the bottom tool on the geometric accuracy and potential strategies, in order to avoid this loss of contact, are also discussed.

Original languageEnglish (US)
Article number061019
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume133
Issue number6
DOIs
StatePublished - Dec 1 2011

Keywords

  • double sided incremental forming
  • forming force
  • geometric accuracy
  • squeezing toolpath

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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