Topic > Incremental Two-Point Sheet Metal Forming

IndexProblem DefinitionScopeObjectiveMethodologyMetal forming is one of the most important industries, which provides 15-20% of GDP and plays a significant role in the manufacturing process. Conventional manufacturing processes such as drawing, deep drawing, stamping and stretch forming enable mass production with a high level of automation but low flexibility. But when it comes to meeting customer needs, the lot gets smaller and smaller. Due to the complex shape of the parts, tooling complexity and costs increase in conventional sheet metal forming processes. Say no to plagiarism. Get a tailor-made essay on "Why Violent Video Games Shouldn't Be Banned"? Get an Original Essay Research has been conducted in recent years to find new ways to meet customer requests for small-batch products. Incremental sheet metal forming is mainly used to meet customer demands. This is a mold-free process and also requires low costs to develop new products. It is mainly used in prototype production. In the incremental sheet metal forming process, a simple hemispherical or ball-ended tool is used to produce local plastic deformation thus forming complex shapes. The forming tool follows a two-dimensional contour. The final shape of the product is obtained by repeating the step layer by layer. So, depending on the new shape of the product, only the CNC program and, if necessary, the forming tool need to be changed. The main elements used in the ISF process are the sheet metal, the blank holder with or without a support plate, the clamping plate, the forming tool and a three-axis CNC machine. The instrument has three degrees of freedom in the x, y and z axes, rotation around its own axis. Depending on the contact between the tool and the blank, ISF is classified into single-point incremental forming, incremental sheet metal forming with counter tools (another tool holder on the other side of the blank), incremental single-point forming two points (deformation occurs in several places with the help of partial or complete matrix support). In the first two types only the tool moves along the programmed path and the blank holder is stationary. But in the third type, the blank holder also moves along with the direction of the forming tool to ensure the mold support. In most cases, CNC milling machines are preferred because they allow high speeds, large work volumes and good rigidity. Special machines have also been developed for the ISF process. The use of industrial robots has advantages such as a large working volume and high flexibility compared to the milling machine. The disadvantages of robots are low rigidity and poor ability to apply large forces. Unlike manufacturing processes, the tools used for the ISF process are not yet standardized. Tools used in CNC milling machine can be straight and hemispherical at the end. The tools used in the CNC lathe are bent. The tool diameter varies from 6 mm to 100 mm for the production of large parts. The selection of materials in the ISF process is made based on the required strength, weight and corrosion resistance. The material most used in the ISF process is aluminum and its alloys. Brass and copper are also used for their formability and lightness properties. Titanium is used for its corrosion resistant properties and magnesium is used for its light weight in many industries. Problem definition Formability, geometric precision, the.