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J. Jeswiet1 (1), F. Micari2 (1), G. Hirt3, A. Bramley4 (1), J. Duflou5 (2), J. Allwood6
1
Keywords:
Forming, Rapid Prototyping, Sheet Metal
1 INTRODUCTION
New methods of forming sheet metal are now at a stage
where it is possible to make either custom manufactured
parts or to manufacture small batch production quantities,
with very short turn around times from design to
manufacture. Schmoeckel [1] predicted in 1991 that with
the increase in automation metal forming equipment would
become more flexible. That has happened in this case.
The idea of incrementally forming sheet metal with a single
point tool, called dieless forming, was patented by Leszak
[2] well before it was technically feasible. There have been
many studies, which have lead to the present situation [3
8]. Today, there are new processes whereby sheet metal
is plastically deformed at a local point enabling truly
flexible production of complex sheet metal parts. This can
be done in either small batch lots with short lead times, or
in production of usable rapid prototypes within one day.
The new processes are attractive because manufacturing
sheet metal can be accomplished by any facility having a
three-axis CNC mill.
Inspiration for the emerging processes is usually found in
traditional forming methods. These conventional processes
are typically constrained as far as achievable part
geometry is concerned and require dedicated tooling and
dies. CNC hardware and software have reached a mature
state of development enabling the development of new
sheet metal forming processes. The new forming methods
give the possibility to create flexible forming facilities,
without dies, capable of producing complex shaped
surfaces, while applying generic tooling. The ultimate goal
is dieless forming.
This paper will show how a product progresses from the
design stage, to developing toolpaths for metal forming, to
the final production process.
Spinning is the forerunner of asymmetric incremental sheet
metal forming. Hagan and Jeswiet [9] sketched a state-ofthe-art for a number of the newly emerging sheet metal
forming processes, all having a genesis in spinning, and all
having a potential for rapid prototyping applications with
sheet metal.
Formed cone
Rotating
Mandrel
Rotating
Mandrel
Initial Blank
Initial Blank
Shear forming
Conventional
spinning
tf
ti
ti
before deformation
ellipsoid
mandrel
spinnability:
t t
%R = i
ti
forming tool
faceplate
counter tool
(b) Incremental Forming
with counter tools
blankholder motion
full die
blank
Bushing
Support Post
y
x
z
2
The small plastic zone and incremental nature of the
r
d
1
d =r
(1 cos(2 ) ; d = max
process contributes to increased formability, making it
2
2
easier to deform low formability sheet.
=
spindle
speed;
=
feed
rate
A conventional CNC milling machine or lathe can be
used for this process.
v
v
=
=
The size of the part is limited only by the size of the
d
1
dmax
machine. Forces do not increase because the contact refer 23()
r (1 cos 2 )
2
zone and incremental step size remain small.
The surface finish of the part can be improved.
Figure 7. Tool geometry and spindle speeds.
The operation is quiet and relatively noise free.
Disadvantages:
To keep friction heat minimal the tool must roll over the
The major disadvantage is the forming time is much
surface of the work piece as it is formed. This result
longer than competitive processes such as deep
requires that the distance traveled along the work piece
drawing.
(i.e. the feed rate) be equal to the average circumference
As a result the process is limited to small size batch
of the tool in contact with the material multiplied by the
production.
spindle speed. The following equation, derived in Figure 7,
The forming of right angles cannot be done in one step,
describes this mathematically. Spindle speed and feed rate
but requires a multi-step process.
are represented by and respectively and the
springback occurs, however algorithms are being
hemispherical tool radius is r.
developed to deal with this problem.
v
(1)
3.3 Forming Tool Spindle speeds
=
1
One major difference between the different sheet
r (1 cos 2 )
incremental forming processes, described by Hagan [9]
2
and other users of the process [29, 30, 31, 32], is the way
the tool moves while deforming the sheet. In the case of
Using Friction Heat
SPIF the following have been done: 1) move the spindle
without rotation, 2) move the spindle with the spindle
Increased spindle rotational speed is used sometimes to
rotating, at different spindle rotating speeds.
increase Formability [35]. The Formability increase is due
to both a local heating of the sheet and, what is more, a
In the second case the spindle rotates so that the forming
positive reduction of friction effects at the tool-sheet
tool rolls over the sheet surface. Controlling this variable
interface.
controls the heating of the sheet during deformation.
Spindle, Free Rotation
Reduced Friction Heating Speeds
In a case study of manufacturing a solar oven cavity, the
The forming tool has a hemispherical shape, which is
spindle could rotate freely in a CNC mill [36]. This allowed
pressed into the material to cause deformation as shown in
the friction at the tool/workpiece to cause the tool to rotate
Figure 9.
at a speed that automatically matched the spindle surface
The most obvious source of heating is friction. As the tool
rotation speed. This method is also used by a machines
travels over the surface of the work piece it is also spinning
specially built for Incremental Forming [37 38, 39, 40].
at a certain number of revolutions per minute. If the tool is
3.4 Equipment used for Incremental Forming
stopped it will slide along the surface of the material. In all
cases heating will occur due to sliding friction. If the tool is
The total package needed to incrementally form sheet
rotated at a high speed, the tool surface will slide over the
metal consists of a forming tool and the machinery that
work piece much more often and there will be excessive
moves the forming tool in a controlled manner. These are
heating. The relative motion of the surface of the tool, to
discussed in the following.
the surface of the work piece, is directly proportional to the
The main element is the single point forming tool. Solid
heat generated by sliding friction.
hemispherical tools are usually used when plastically
If the relative motion between the tool surface and
deforming sheet metal incrementally. A wide variety of
workpiece is small during forming (i.e. all friction is rolling
solid tools is used, however, other types of tooling, such as
friction, and not sliding friction) the heating is minimized.
water jets, are being investigated and these are reviewed.
Tools are designed and made by the users, they are not
For the draw angle, , there will be a point where the sheet
yet part of an assortment made available in the market.
is tangent to the hemisphere. This is the location of the
maximum diameter of contact (dmax). From then on the
Solid Forming tools
work piece is in contact with the tool down to the very
A solid hemispherical head is generally used for
bottom of the sphere, at which point the diameter of
asymmetric single point incremental forming; see Figure 8.
contact is zero. This is an assumption. The average
This assures a continuous point contact between sheet
diameter of contact is therefore half dmax, see Figure 7.
and forming tool; see Figure 7. At very steep wall angles it
Sleeve, z-axis
Socket (fixed)
Flange
(rotating collet)
Pressure fluid
ca. 320 bar
Forming
tool
aperture
CBN-ball
13 mm
Definitions:
d = largest draw angle in a CAD
max = the maximum draw angle for
a material
Embed shape in
the sheet metal
surface; use
minimum angles.
Check
forming limit
diagrams for
formability.
Check for
the largest
d ;
if d > max
List of materials
available and
their properties
Second check
of forming limit
diagrams for
formability.
Check
where the
maximum
d occurs
Choose a material.
Find the maximum
draw angle, max
for that material.
d < max.
d > max.
Generate toolpath
Use two pass
method
D0
10 mm
max
Material
AA 1050-O
FLDo
67.5 2.305
to , mm
1.21
Filice [31]
1.0
Micari [63]
AA 6114T4
60
Al 3003 O
78.1
2.1
Jeswiet [59]
Al 3003 O
72.1
1.3
Jeswiet [59]
Al 3003 O
71
1.21
Jeswiet [59]
Al 3003 O
67
0.93
Jeswiet [59]
Al 5754 O
62
1.02
Jeswiet [59]
Al 5182 O
63
0.93
Jeswiet [59]
AA 6111T4P
53
0.93
Jeswiet [59]
65
1.2
1.0
Hirt [65]
DDQ
70
2.718
1.0
Micari [63]
HSS
65
1.924
1.0
Micari [63]
Copper
65
1.808
1.0
Micari [63]
Brass
40
0.701
1.0
Micari [63]
0.841
3.0
to = 1.5mm
= 40, t1 = 1.15mm
= 60, t2 = 0.75mm
to= 1.5mm
(2)
AA 5754O
max = 3.3to + 58.3
(3)
The upper and lower limits to the linear function are
defined by spinnabillity [18] and the sine law. Although the
these linear functions have limitations, they are useful to
the designer in giving choices for combinations of
thickness and draw angle for single pass forming.
3.5
max, FLDo
Upper limit
2.5
2
1.5
Lower limit
1
0.5
0
0.00
1.00
2.00
3.00
4.00
Depth of step, z, mm
Figure 18: FLDo for different step sizes for AA 1050-0, with
upper and lower bounds, with a 12 mm diameter tool [59].
2.0
1.8
1.6
6 mm
tool
Major strain
1.4
1.2
1.0
0.8
10 mm
tool
30 mm
tool
1
2
4
x 2
x
1 x
1.0
0.9
0.6
0.2
0
0.8
0.4
0.7
0.6
0.5
0.4
0.3
0.2
0.1
-0.2 -0.1 0
max
2.5
min = max + 3
2,5
2
1,5
1.5
1
0.5
-1.0
-0.5
0,5
0.5
1.0
0
min
Figure 21: Composite FLD for five parts formed by
asymmetric single point incremental forming of 1.21 mm
thick AA 3003-0 [62]. Each colour a shape and each point
represents a successfully formed shape.
4.4 Formability and material properties
Materials all have different formabilities and Table 1 in
section 4.2 shows how materials have a different
maximum draw angle max. In most sheet metal operations,
formability is limited by a local necking instability. Once a
neck is initiated the high hydrostatic stress that develops
within the neck leads to rapid void nucleation, growth and
coalescence [60, 72]. However, in certain forming
operations, such as bending and stretch flanging, necking
is suppressed and formability is controlled by the evolution
of void damage and shear band instability. If the strain is
evenly distributed in the metal, as it is in SPIF, very large
strains can be achieved due to the foregoing void damage
and shear band instability.
A comprehensive analysis was instigated to understand
the correlations between material formability and other
material properties [59]. The experimental campaign was
developed with a set of different blank materials, typically
utilized in the automotive and other sheet forming
industries. The materials used and their main
characteristics are summarized in the Table 2.
As before, the formability results were formalized again
through the FLDo values, while the testing parameters
were fixed for all the experiments. An FLD of all the
materials in table 2 is shown in Figure 22.
An FLD does not give information on which material
parameters predominate. Therefore a statistical analysis
was carried out to determine the influence of the material
properties in table 2. Five variables (K, n, Rn, UTS, A%)
were chosen as inputs, each one with five replications with
-0,5
-0,25
0
0,25
0,5
Copper
HSS
AA6114
Brass
DDQ
AA 1050 - O
Figure 22: An FLD of the material parameters shown in
Table 2 [59].
FLDo fixed as the output. The intention of the analysis was
to determine how each input variable influenced the output
parameter. The experimental results were analysed by a
response surface statistical model where the qualitative
influence of the predictors (pure linear terms and
interactions among inputs, i.e. hybrid quadratic terms) on
FLDo were reported. The results indicate the highest
influence on material formability for AISF processes is the
strain hardening coefficient, n. In addition, there is a high
influence of a combined strength coefficient and strain
hardening coefficient. Strength coefficient and elongation
also have an influence upon the formability. The statistical
analysis leads to a six dimension hyper-surface:
FLDo = 8.64 - 36.2n - 0.00798K + 0.373Rn - 0.104A% +
0.0301Kn + 0.607n A% [59].
(4)
Jeswiet et al. [66] also found that both strength coefficient
and strain hardening coefficient had a major influence and
that a more accurate model of the stress-strain condition
could be obtained with a Voce model [71]. Verification of
this can be found in work by Lievers et al. [72] who
investigated three different automotive aluminum alloys in
developing a model of stress strain characteristics:
AA5182-0, AA5754-0 and AA6111-T4P. Their model
shows the Hollomon-Ludwig [73] relationship fits the
stress-strain curve at low values of strain, but at higher
strains the plastic section of the curve was more accurate
when fit to a Voce curve of the form:
(5)
M = s s y eq
where
( )
q = Mp
t
mm
MPa
MPa
AA5182-0
0.93
0.88
118
379
7.35
0.890
AA5754-0
1.02
0.76
93
298
7.48
0.844
AA6111-T4P
0.93
0.70
164
455
5.42
0.837
5050?m
m
DC04, initial state
505 m
?m
o
DCO4, = 80 , z = 1.75mm
0.14
= 152
0.213
[67]
(6)
[76, 77]
(7)
100
m
5 ?m
100?
m
1.4301, initial state
505 m
?m
o
1.4301, = 80 , z = 1.75mm
x2
z2
h2
x1
material
ridge
z1
h1
z = 1.27mm
z = 0.76mm
z = 0.51mm
z = 1.02mm
1.78 mm z
1.27 mm
0.51 mm
Profile height, mm
0.03
0.02
0.01
tool profile
-2.5 -2
0
-1.5 -1 -0.5 0
0.5 1
1.5
Distance Along Surface (mm)
2.5
RZ [m]
19,1
20
15
10
5
0
11,5
as received
roughness
3,3
2,5
1,9
1,1
1,7
0,9
0.1
10,1
4,5
4,1
4,8
3,9
0.2
0.5
Pitch z, mm
10,4
20
15
10
5
7,3
47
65
m
47
5m
65
mm
m
1.0
15
,m
s
u
i
Wall angle
rad
ol
o
T
600
500
400
20
30
40
50
60
300
200
100
0
750
500
1000 1250
Time, s
Figure 31: Total force curves for conical parts with different
drawing angles for a 0.5 mm vertical step size, 10 mm tool
diameter, feed rate of 2000 mm/min [81].
500
450
400
350
300
250
200
150
100
50
0
- 50
Ft
10
20
80
30
40 50
60
70
Percentage Complete
Peak forces
observed
N, ( lbf)
712, (160)
623, (140)
534, (120)
445 N
445, (100)
356, (80)
forming tool
60o
b
45o
289 N
(60)
cone 30
cone 45
(40)
(20)
0
F45o F60
596 N
30o
cone 60
a
250
500
Process
parameter
F(N)
R2
Tool diameter
(in mm)
Fp=12.761 +434.5
Fs=12.812 +410.8
Fp=6.793 +210.4
0.9826
2
Fs=-0.2284 +22.753 0.9919
47.0
Fp=151.58 z +466.9
Fs=148.13 z +447.17
0.9809
0.9884
0.9655
0.9725
Force
D
of irec
to tio
ol n
Forces measured in
TPIF of AA 3003-0
10.0
12.7
15.0
20.0
25.0
Figure 32: Force curves for parts formed with tools from a
10 mm to 25 mm diameter [81].
Ft
Fr
250
800
700
600
500
400
300
200
100
0
Fa
Fb
Fr
tool
path
Force, N
10 20 30 40 50 60
# of Profile from top to bottom
70 80
1.40
1.20
Thickness, mm
1.00
0.80
0.25 mm
0.37 mm
0.60
0.40
0.20
0.00
0
10
20 30
40
50 60
70 80 90
forming
tool
offset
4.8
Toolpath Generation
Once all the material characteristics are known a toolpath
can be planned. There are several choices available for
the forming toolpath shown in the following.
1.21 mm
bending
applied force
0.65 mm
4.7 Multiple
pass
asymmetric
single
point
incremental forming
To remedy thinning shown in the discrete zone in Figure
33, and to avoid failures, material available elsewhere in
the part can be used to stop both thinning and failure. In
their work on SPIF Kim and Yang [85] used a pre-form, or
two-pass forming as a means of equalizing the strain
distribution across the surface of a part. Jeswiet and
Hagan [29], and Hirt et al [61] also used the same
technique. This involves the creation of high strains in a
pre-form at areas where low strains are present in the final
geometry, and low strains at areas where high strains are
present on the final geometry [83]. Pre-forms can then be
designed to include a combination of wall angles and
artificially large offsets from the backing plate.
The hypothesis behind the steep wall angles and large
offsets is that this encourages the undeformed sheet in the
flange area to bend downwards over the backing plate and
into the part. This presents a thick surface that is already
inclined at a portion of the final angle desired in the
finished geometry. When shear forming theory for preformed blanks is consulted, a two-pass sine law is
employed [83, 84] as follows:
tf = tp
Sin ( f )
Sin ( p )
(7)
Top surface
Top radius RTop
Flange
Preform area
sheet thickness t, mm
Blank
Bottom radius RB
1.6
1.4
1.2
1.0
0.8
o
sine
law;
Sine
lawf = 45
0.6
o
1100-0
Material: Al99.5
sine law; f = 81
0.4 Thickness:
to=1.5mm
s0=1.5mm
RR=15mm
0.2 Tool:
TT=15mm
Angle: =81
= 81o
0.0
0
20
40
60 80 100 120 140 160
Rtop
Top surface
Blank
Rblank
Preform area
x- coordinate [mm]
Flange
1st contour
upshot of the tests was the type of lubricant did not appear
to be a factor, but lubrication is necessary to obtain a
smooth surface. Table 5 shows results from some tests.
Shape
lubrication
Spindle
rpm
1000
Ra
mm
9.42
Rt
mm
74.73
sphere
none
pyramid
grease
1000
1.24
14.43
sphere
oil
20
0.538
5.09
pyramid
grease
20
0.564
5.43
Thinning [%]
60
50
40
30
20
10
5
experiment
explicit FEA
implicit FEA
0
z [mm]
-5
-10
-15
-20
-25
10
20
30
40
x [mm]
50
60
70
Dt [s]
dmax
mm
implicit
0.004
1.09 0.59
11.7
7.32
explicit
15.6
0.58
3
2
1
0
-1
-2
-3
pl,
0.0
0.1
0.2
0.3
normalised process time
0.4
Test 1 Test 2
Absolute 1.327
1.113
Test 3 Test 4
1.317
0.955
0.379
1.513
1.067
0.305
-1.55
-0.58
-0.79
-0.47
Minimum
-4.47
-1.78
-2.75
-2.06
Maximum
4.137
5.398
4.223
0.980
Sigma ()
1.727
1.221
1.169
0.508
Cross
Hexagon
5 lobe
shape
Faceted
cone
Multi-shaped surface
V shaped
tub
Cone
Dome
Hyperbola
Truncated pyramid
z
z
IGES file
x
z = 0.4 mm
y
74 mm
2002 vehicle
headlight
2002 vehicle
headlight
Automotive
heat/noise
shield
A
B
z = 0.3 mm
Finished part
inside
inside
outside
aluminized
Table 9: Rapid prototypes for automotive industries [29].
IGES file
Solar oven
cavity.
Motorbike
seat
Motorbike
gas tank
Finished part
inside
outside
surface
outside
gl a
ss
lid
cooking
cavity
Figure 51: The x-z profile of CAD file and formed product.
The outside of the solar oven is shown as an inset. The
springback can be observed [36].
5.3 A Medical Application of SPIF
The medical industry can benefit greatly by using the SPIF
process to either produce Rapid Prototypes or one-off
parts. The following is an application of asymmetric
incremental forming of a customized medical product, i.e.
an ankle support. The steps to go from the request for a
part to the final manufacture are shown in Figure 52.
The application addressed here represents a Reverse
Engineering (RE) application; it permits the reproduction of
high accuracy models called from complex geometries. By
employing RE, it is possible to create lifelike 3D models
representing many different objects including parts of a
human body.
In this application, SPIF was used to produce a part that is
used as an ankle support.
The process includes the following steps:
first, the three-dimensional scanning of a human ankle
with a laser (non contact inspection) is carried out in
order to obtain the morphological and dimensional
information of the object;
next, once the data is available in a digital format, a
cloud of points is built, from which is possible to
develop the surfaces that individualize the shape ankle;
finally, through the application of CAD/CAM Systems, an
ISO part program is generated. This is handed over to
the numerical control machine, which carries out the
Incremental Forming operation.
Laser scanning is used because it has a large number of
advantages, such as: low operation costs and easy
acquisition; small dimensions; real time results.
The application addressed here was carried out with a
system that works according to triangulation principles.
This permits the measurement of small objects, with a
scan in six tenths of a second. The system permits
recording of the object including surface features such as
colour and luminosity.
The next step is surface building or editing with software.
This uses multiple observations during scanning, and since
the object investigated is observed from many different
angles markers are used on the surface. The software
develops the parametric surfaces, which are used to obtain
the solid model of the ankle.
CAD Model
Real Model
Laser Scanner
Virtual Model
Production
Request for an
Ankle Support
CAD/CAM
interface
shape embedding
`````
Figure 52: The manufacture of an ankle support, from request, to scanning of a live subject (reverse engineering), to setting up
a solid model and CAD drawing, to embedding the shape for toolpath planning, to creating a toolpath for manufacture, to
checking for accuracy [59].
Strength
coefficient
Hardening
exponent
Anisotropy
Tensile
Strength
Elongation
%
K = 545
MPa
n = 0.27
= 2.01
R = 290
MPa
A% = 50
[4]
[5]
[6]
[7]
[8]
[9]
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Jrgensen, T. H., Moos, N., 2002, Applications of RP
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th
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[89]
[90]
[91]
[92]
[93]
[94]
[95]
[96]