The presented research aimed to improve the knowledge on process variables and to show the importance of tool path design in two point incremental forming with full die. Several indications about the sheet behaviour, as a function of two different tool path strategies, were obtained. In particular, the performed tests demonstrate that, in order to reach good results in terms of surface quality, geometric accuracy and thickness distribution of the final part, it is important to correctly set the value of two parameters: step depth and scallop height. The best choice, as shown, is to set low values for both of these parameters (Delta Zmax 0.2mm and maximum scallop 0.02 mm) even if the working time increases. It is fundamental, in ASIF designing phase, to consider the final use of the component. If it is a structural part it is better to minimize the working times setting higher scallop height values, while if it is an aesthetic component the final part accuracy becomes more relevant than the total working time. In general, the SIF process can be successfully used either to manufacture or to finish pre-produced prototypes using the same sheet material of the series production and guaranteeing the geometrical and aesthetic requirements without the need of too expensive prototyping dies. Further analyses are going to be performed in order to improve the part dimensional accuracy and to evaluate other important process features like forces acting on the tool and sheet springback in ASIF with full die. Moreover, a simulative model was developed and the first results show the FEM capability to represent the ASIF process. For the future, an extensive simulative campaign will be developed with the aim of investigating the effect of the process parameters, such as sheet thickness, tool path (in terms of AZ and limit scallop height) and tool feed and speed, on sheet thickness distribution and part geometrical errors. The main advantages of having a FEM model are the testing costs reduction (related with the machine, the tool and the labour costs, and the test duration) and the possibility of identifying the best working conditions in terms of die and blankholder geometries, sheet preform and process parameters. Of course it must be pointed out that in the simulations the calculation time is a key factor. Robust tool path and increasing computational power can make simulative programs a valid alternative in process parameters identification and optimization.


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    Titel :

    Asymmetric two points incremental forming: Improving surface quality and geometric accuracy by tool path optimization


    Beteiligte:
    Attanasio, A. (Autor:in) / Ceretti, E. (Autor:in) / Giardini, C. (Autor:in) / Mazzoni, L. (Autor:in)

    Erschienen in:

    Erscheinungsdatum :

    2008


    Format / Umfang :

    9 Seiten, 17 Bilder, 2 Tabellen, 19 Quellen




    Medientyp :

    Aufsatz (Zeitschrift)


    Format :

    Print


    Sprache :

    Englisch








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