RP of Sheet Metal using Single Point Incremental Forming[SPIF]

BY

SUDHEER KUMAR

SAI KIRAN

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CONTENTS

Introduction

SPIF process configurations

Tool path strategies

Adaptive Slicing

Applications

Conclusions

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RP as an ADDITIVE MANUFACTURING 3

Incremental Sheet Metal Forming[ISMF]

Features

Localised deformation

Increased Formability

Flexible to form complex geometrical shapes

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SPIF process configuration

Negative forming process Positive forming process

a) Without Die

b) With Die

a) Using partial support

b) Using full support

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Negative ISMF process

Where the tool moves in negative Z direction

in incremental steps

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Positive ISMF process

Where a rigid member

support from the bottom

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Other Variants of ISMF processes

Two point incremental sheet metal forming

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Other Variants of ISMF processes 9

Tool Path Strategies 10

Tool Path generation

3 tool path generation methods are presented here.

i) Horizontal slicing

ii) Inclined Slicing

iii) Offset method

Tool path always generated starting from outer loop of feature

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Horizontal Slicing

suitable for features with horizontal inner and outer loops.Constant slicing height(∆z) is used

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Inclined slicing

Slicing features with non-parallel outer and inner loops

Planes rotating about an axis are used for slicing

Axis of rotation is intersection of outer loop plane and inner loop plane

Slice thickness is not constant

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Offset method

Tool path for features which can not be sliced because of height smaller than slicing height.

Outer and inner loops are joined with straight lines as shown.

Equal number of equidistant points are generated on each line.

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Slicing Strategies 15

Cup with inclined hump model 16

Forming sequence 17

Different geometrical shapes formed by ISMF

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Applications

Conical geometrical part

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Applications 20

Applications 21

Applications 22

Applications

Complex automotive parts. Amino KK. Japanese company

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Applications 24

Conclusions

ISMF does not require dies. So changes in the design can be easily and economically incorporated .

Adaptive slicing is possible to attain higher accuracies in the part.

Formability in ISMF is much higher than that of traditional forming processes, and there by complex geometries can be made.

ISMF process is relatively new and emerging field and research need to be done for improving the accuracy and calculation of specific forces required.

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Thank You

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