Incremental forming (IF) is a relatively new technique that uses a simple hemispherical ended tool moving along a predefined three-dimensional toolpath to deform a sheet of metal into the desired shape. The greater process flexibility and higher formability in IF have resulted in greater academic and industrial interest in this process as it can successfully produce ultrathin parts beyond the forming limit seen in conventional stamping and the process does not require any geometry-specific tooling. Another emerging paradigm in manufacturing has been the increasing application of forming in micromanufacturing. The above stated process characteristics of IF make it an ideal candidate for being incorporated into the micromanufacturing paradigm. This work investigates micro-IF to examine how forces and occurrence of sheet failure change when the geometric dimensions of incremental forming are scaled down. The development of a highly repeatable micro-IF experimental setup is described and experiments are performed to show that a previously unknown buckling mode of deformation exists in micro-incremental forming, that is linked to the material microstructure. The analysis provides guidelines for the design and understanding of the micro-incremental forming process.
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Northwestern University,
Indian Institute of Technology,
Northwestern University,
e-mail: jcao@northwestern.edu
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September 2013
Research-Article
Experimental Study of Failure Modes and Scaling Effects in Micro-Incremental Forming
A. J. Nelson,
Northwestern University,
A. J. Nelson
Department of Mechanical Engineering
,Northwestern University,
Evanston, IL 60201
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N. V. Reddy,
Indian Institute of Technology,
N. V. Reddy
Department of Mechanical Engineering
,Indian Institute of Technology,
Kanpur 208016
, India
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Jian Cao
Northwestern University,
e-mail: jcao@northwestern.edu
Jian Cao
1
Department of Mechanical Engineering
,Northwestern University,
Evanston, IL 60201
e-mail: jcao@northwestern.edu
1Corresponding author.
Search for other works by this author on:
A. J. Nelson
Department of Mechanical Engineering
,Northwestern University,
Evanston, IL 60201
N. V. Reddy
Department of Mechanical Engineering
,Indian Institute of Technology,
Kanpur 208016
, India
Jian Cao
Department of Mechanical Engineering
,Northwestern University,
Evanston, IL 60201
e-mail: jcao@northwestern.edu
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF Micro- AND Nano-Manufacturing. Manuscript received November 20, 2012; final manuscript received July 24, 2013; published online xx xx, xxxx. Assoc. Editor: Shiv G. Kapoor.
J. Micro Nano-Manuf. Sep 2013, 1(3): 031005 (15 pages)
Published Online: August 13, 2013
Article history
Received:
November 20, 2012
Revision Received:
July 24, 2013
Citation
Beltran, M., Malhotra, R., Nelson, A. J., Bhattacharya, A., Reddy, N. V., and Cao, J. (August 13, 2013). "Experimental Study of Failure Modes and Scaling Effects in Micro-Incremental Forming." ASME. J. Micro Nano-Manuf. September 2013; 1(3): 031005. https://doi.org/10.1115/1.4025098
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