Investigating the Effect of Rotation Speed and Ultrasonic Vibrations in the Incremental Forming Process

Subject Areas : advanced manufacturing technology

Saeed  Amini ¹ (Department of Mechanical Engineering, University of Kashan, Iran)
Farshad  Nazari ² (Department of Mechanical Engineering, University of Kashan, Iran)
Mohammad  Baraheni ³ (Department of Mechanical Engineering, University of Kashan, Iran)
Amir Hossein  Ghasemi ⁴ (Department of Mechanical Engineering, University of Kashan, Iran)

Received: 2018-06-14 Accepted : 2018-12-17 Published : 2018-12-17

Keywords: Surface Roughness, Rotating Tool, Incremental Forming, Ultrasonic Vibrations, Formability,

Abstract :

Incremental forming is one of the forming methods that is considered because of no need to specific die, especially for rapid prototyping. In this study, the incremental forming process is carried out by using a rotating tool and assisted ultrasonic vibration. Purpose of this research is to investigate the effect of rotation speed and ultrasonic vibrations in the incremental forming process. According to the obtained results, mean and maximum values of forming force reduced by using a rotating tool and applying ultrasonic vibrations. The results of surface roughness tests demonstrated that by increasing rotational speed, the surface roughness improved 44% and applying ultrasonic vibrations with tool rotation can reduce surface roughness about 74%. Applying ultrasonic vibrations lead to increase micro-hardness up to 84%, but, by increasing rotational speed, surface hardness slightly reduces. Results of straight groove test determined ultrasonic vibrations with the rotating tool can increase stretching limit up to 41.79% due to the affect on the sheet plasticity behavior.

References:

[1]     Governale, A., Lo Franco, A., Panzeca, A., Fratini, L., and Micari, F., Incremental Forming Process for the Accomplishment of Automotive Details, Key Engineering Materials, Vo. 344, 2007.

[2]     Groche, P., Fritsche, D., Tekkaya, E., Allwood, J., Hirt, G., and Neugebauer, R., Incremental Bulk Metal Forming, CIRP Annals, Vol. 56, No. 2, 2007, pp. 635-656.

[3]     Kleiner, M., Geiger, M., and Klaus, A., Manufacturing of Lightweight Components by Metal Forming, CIRP Annals-Manufacturing Technology, Vol. 52, No. 2, 2003, pp. 521-542.

[4]     Merklein, M., Allwood, J., Behrens, B. A., Brosius, A., Hagenah, H., Kuzman, K., Mori, K., Tekkaya, A., and Weckenmann, A., Bulk Forming of Sheet Metal, CIRP Annals-Manufacturing Technology, Vol. 61, No. 2, 2012, pp. 725-745.

[5]     Mori, K. i., Nonaka, T., Simplified Three-Dimensional Finite Element Simulation of Shear Spinning Process Based on Axisymmetric Modeling, Journal of Manufacturing Processes, Vol. 7, No. 1, 2005, pp. 51-56.

[6]     Iseki, H., Kato, K., and Sakamoto, S., Flexible and Incremental Sheet Metal Forming Using a Spherical Roller, Proc. 40th JJCTP, Vol. 41, 1989, pp. 44.

[7]     Asghari, S. A. A., Shamsi Sarband, A., and Habibnia, M., Optimization of Multiple Quality Characteristics in Two-Point Incremental Forming of Aluminum 1050 by Grey Relational Analysis, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, pp. 0954406217693658.

[8]     Seong, D., Haque, M., Kim, J., Stoughton, T., and Yoon, J., Suppression of Necking in Incremental Sheet Forming, International Journal of Solids and Structures, Vol. 51, No. 15-16, 2014, pp. 2840-2849.

[9]     Raujol-Veillé, J., Toussaint, F., Tabourot, L., Vautrot, M., and Balland, P., Experimental and Numerical Investigation of a Short, Thin-Walled Steel Tube Incremental Forming Process, Journal of Manufacturing Processes, Vol. 19, 2015, pp. 59-66.

[10]  Li, Y., Daniel, W. J., Liu, Z., Lu, H., and Meehan, P. A., Deformation Mechanics and Efficient Force Prediction in Single Point Incremental Forming, Journal of Materials Processing Technology, Vol. 221, 2015, pp. 100-111.

[11]  Araghi, B. T., Manco, G., Bambach, M., and Hirt, G., Investigation into a New Hybrid Forming Process: Incremental Sheet Forming Combined with Stretch Forming, CIRP Annals, Vol. 58, No. 1, 2009, pp. 225-228.

[12]  Duflou, J., Callebaut, B., Verbert, J., and De Baerdemaeker, H., Laser Assisted Incremental Forming: Formability and Accuracy Improvement, CIRP Annals-Manufacturing Technology, Vol. 56, No. 1, 2007, pp. 273-276.

[13]  Fan, G., Gao, L., Hussain, G., Wu, Z., Electric Hot Incremental Forming: a Novel Technique, International Journal of Machine Tools and Manufacture, Vol. 48, No. 15, 2008, pp. 1688-1692.

[14]  Cui, X., Li, J., Mo, J., Fang, J., Zhu, Y., and Zhong, K., Investigation of Large Sheet Deformation Process in Electromagnetic Incremental Forming, Materials & Design, Vol. 76, 2015, pp. 86-96.

[15]  Jurisevic, B., Kuzman, K., and Junkar, M., Water Jetting Technology: an Alternative in Incremental Sheet Metal Forming, The International Journal of Advanced Manufacturing Technology, Vol. 31, No. 1-2, 2006, pp. 18-23.

[16]  Xu, D., Wu, W., Malhotra, R., Chen, J., Lu, B., and Cao, J., Mechanism Investigation for the Influence of Tool Rotation and Laser Surface Texturing (LST) on Formability in Single Point Incremental Forming, International Journal of Machine Tools and Manufacture, Vol. 73, 2013, pp. 37-46.

[17]  Lu, B., Fang, Y., Xu, D., Chen, J., Ou, H., Moser, N., and Cao, J., Mechanism Investigation of Friction-Related Effects in Single Point Incremental Forming Using a Developed Oblique Roller-Ball Tool, International Journal of Machine Tools and Manufacture, Vol. 85, 2014, pp. 14-29.

[18]  Ebrahimzadeh, P., Baseri, H., and Mirnia, M. J., Formability of Aluminum 5083 Friction Stir Welded Blank in Two-Point Incremental Forming Process, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2017, pp. 0954408917692370.

[19]  Centeno, G., Bagudanch, I., Martínez-Donaire, A. J., Garcia-Romeu, M. L., and Vallellano, C., Critical Analysis of Necking and Fracture Limit Strains and Forming Forces in Single-Point Incremental Forming, Materials & Design, Vol. 63, 2014, pp. 20-29.

[20]  Bagudanch, I., Garcia-Romeu, M., Centeno, G., Elías-Zúñiga, A., and Ciurana, J., Forming Force and Temperature Effects on Single Point Incremental Forming of Polyvinylchloride, Journal of Materials Processing Technology, Vol. 219, 2015, pp. 221-229.

[21]  Vahdati, M., Mahdavinejad, R., and Amini, S., Investigation of the Ultrasonic Vibration Effect in Incremental Sheet Metal Forming Process, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 231, No. 6, 2017, pp. 971-982.

[22]  Ambrogio, G., Filice, L., and Micari, F., A Force Measuring Based Strategy for Failure Prevention in Incremental Forming, Journal of Materials Processing Technology, Vol. 177, No. 1-3, 2006, pp. 413-416.

[23]  Pak, A., Deilami Azodi, H., and Mahmoudi, M., Investigation of Ultrasonic Assisted Incremental Sheet Metal Forming Process, Modares Mechanical Engineering, Vol. 14, No. 11, 2015.

[24]  Ngan, A., Physical Metallurgy and Advanced Materials, Elsevier Science & Technology, 2007,

[25]  Malaki, M., Ding, H., A Review of Ultrasonic Peening treatment, Materials & Design, Vol. 87, 2015, pp. 1072-1086.

[26]  Pandivelan, C., Jeevanantham, A., Formability Evaluation of AA 6061 Alloy Sheets on Single Point Incremental Forming Using CNC Vertical Milling Machine, J. Mater Environ Sci, Vol. 6, 2015, pp. 1343-1353.