Iranian Journal of Mechanical Engineering Transactions of ISME

Iranian Journal of Mechanical Engineering Transactions of ISME

Investigation of two point incremental sheet metal forming evaluation applying the finite element method and experimental study

Authors
Farhad Rabiei
Seyed Mohsen Safavi
Mahmood Kadkhodaie
Alireza Saberi
Abstract
Necessity of using لزوم بهکار گیری انواع فلزات در جنسها و شکلها ی متفاوت در فعالیتهای مختلف انسان، او را م لزم ساخته است تا همواره با ابداع روشهایی نوین، در راستای شکلدهی و تغییر شکل قطعاتtypes of metals in many kinds and shapes in human different activities, has always obliged him by invention of new ways, plods in forming and transfiguration of metal parts field.از میان روشهای نوپا در فرآیندهای شکلدهی در حیطهی ورقها، در این تحقیق به بررسی تکنیکی جدید با نام " شکلدهی تدریجی ورقهای فلزی" پرداخته شده. In this article, Two Point Incremental Forming (TPIF) as a new process is introduced by means of which shell parts can be produced with a variety of applications. Incremental sheet metal forming has demonstrated its great potential to form complex three dimensional parts without using a matching die. The process locally deforms sheet metal using a moving tool head achieving higher forming limits than those of conventional sheet metal stamping process. Potential application areas include aerospace industries, customized products in biomedical applications and prototyping in the automotive industry. In this special kind of forming operation, in order to decrease the force during of process and increase formability of sheet metal is used a spherical tool with small dimension. In this process, sheet metal is inserted on a punch with special shape and produced required deformation by incremental movement of tool. In this article, behavior of sheet metal is examined through using experimental and theoretical analysis in Two Point Incremental Forming. Finite element analysis of Incremental Sheet Metal Forming is one of the important issues in this article. The importance of this issue, increases when movement of tool in an accurate path (in accordance to received path from the tool controller), is simulated in the software. در این صورت ، تعریف چندین هزار مرحله ی حرکت ( مربوط به مسیر ابزار ) ، ضروری به نظر می رسد .In this case, it seems necessary definition of several thousand points of movement (related to the tool path) in software. In this thesis, by using a new method, the controlled movement of tool is modeled in ABAQUS software based on received points from the controller. According to the results obtained from finite element simulation, is provided the possibility of increasing formability of sheet metal and effective parameters in incremental forming. Moreover, in this research force as important and influential parameter in a forming process is measured. According to results of experimental tests and theoretical analysis, is presented comprehension decision about the forming mechanism in this process. It should be noted that, in this effort the measurement and online observation of process force, has been implemented by two loadcell sensors and LabVIEW software that is new and innovative method.
Keywords
Incremental sheet metal forming
Finite element
Experimental study
Mechatronic tools
Force measurement
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Iranian Journal of Mechanical Engineering Transactions of ISME
Volume 15, Issue 3 - Serial Number 32
System Dyanamics and Solid Mechanics
Autumn 2013
Pages 22-36

  • Receive Date 22 November 2013