Incremental sheet forming (ISF) is a flexible sheet metal forming process that enables forming of complex three-dimensional components by successive local deformations without using component-specific tooling. ISF is also regarded as a die-less manufacturing process in the absence of part-specific die. Geometric accuracy of formed components is inferior to that of their conventional counterparts. In single-point incremental forming (SPIF), the simplest variant of ISF, bending near component opening region is unavoidable due to lack of support. The bending in the component opening region can be reduced to a larger extent by another variant of ISF, namely, double-sided incremental forming (DSIF) in which a moving tool is used to support the sheet locally at the deformation zone. However, the overall geometry of formed components still has unacceptable deviation from the desired geometry. Experimental observation and literature indicate that the supporting tool loses contact with the sheet after forming certain depth. This work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflections due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap of deformation zone that occurs during forming (instead of using sine law). A number of examples are presented to show that the proposed methodology works for a variety of geometries (axisymmetric, varying wall angle, free-forms, features above and below initial sheet plane, and multiple features). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths using DSIF, and support tool maintains contact with sheet throughout the forming process.
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September 2016
Research-Article
Deflection Compensations for Tool Path to Enhance Accuracy During Double-Sided Incremental Forming
Lingam Rakesh,
Lingam Rakesh
Department of Mechanical and
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: Me13p1009@iith.ac.in
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: Me13p1009@iith.ac.in
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Srivastava Amit,
Srivastava Amit
Department of Mechanical Engineering,
Indian Institute of Technology Kanpur,
Kanpur 208016, Uttar Pradesh, India
e-mail: amitigcar@gmail.com
Indian Institute of Technology Kanpur,
Kanpur 208016, Uttar Pradesh, India
e-mail: amitigcar@gmail.com
Search for other works by this author on:
N. V. Reddy
N. V. Reddy
Department of Mechanical and
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: nvr@iith.ac.in
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: nvr@iith.ac.in
Search for other works by this author on:
Lingam Rakesh
Department of Mechanical and
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: Me13p1009@iith.ac.in
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: Me13p1009@iith.ac.in
Srivastava Amit
Department of Mechanical Engineering,
Indian Institute of Technology Kanpur,
Kanpur 208016, Uttar Pradesh, India
e-mail: amitigcar@gmail.com
Indian Institute of Technology Kanpur,
Kanpur 208016, Uttar Pradesh, India
e-mail: amitigcar@gmail.com
N. V. Reddy
Department of Mechanical and
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: nvr@iith.ac.in
Aerospace Engineering,
Indian Institute of Technology Hyderabad,
Kandi,
Sangareddy 502285, Telangana, India
e-mail: nvr@iith.ac.in
1Corresponding author.
Manuscript received November 15, 2015; final manuscript received June 13, 2016; published online July 19, 2016. Assoc. Editor: Rajiv Malhotra.
J. Manuf. Sci. Eng. Sep 2016, 138(9): 091008 (11 pages)
Published Online: July 19, 2016
Article history
Received:
November 15, 2015
Revised:
June 13, 2016
Citation
Rakesh, L., Amit, S., and Reddy, N. V. (July 19, 2016). "Deflection Compensations for Tool Path to Enhance Accuracy During Double-Sided Incremental Forming." ASME. J. Manuf. Sci. Eng. September 2016; 138(9): 091008. https://doi.org/10.1115/1.4033956
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