12/04/2018 PDE Details

College : SARDAR VALLABHBHAI PATEL INSTITUTE OF TECHNOLOGY, VASAD

Department : Mechanical Engineering
Discipline : BE
Semester : Semester 8
Project Name : Parametric analysis on tool shape for SPIF(Single Point Incremental Forming)
Team ID : 17218

Form 1 – APPLICATION FOR GRANT OF PATENT

Applicants :
Sr.
Name Nationality Address Mobile No. Email Id
No
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Lalchandani Kunal PATEL INSTITUTE
1 Indian 9727281868 kunal.140410119037@gmail.com
Nanak OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Bhagat Akshay PATEL INSTITUTE
2 Indian 7043131157 akshay.140410119006@gmail.com
Tolaram OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Dayama Zukhruf PATEL INSTITUTE
3 Indian 9173447279 zukhruf.140410119017@gmail.com
Atiq OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
4 Patel Paurav Kunal Indian Mechanical 9537554577 paurav.140410119090@gmail.com
Engineering ,
SARDAR
VALLABHBHAI
PATEL INSTITUTE
OF TECHNOLOGY,
VASAD ,
Gujarat

1/6
12/04/2018 PDE Details

Technologycal
University.
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Chawla Avinash PATEL INSTITUTE
5 Indian 7048638631 avinash.140410119015@gmail.com
Jagdish OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
Inventors :
Sr.
Name Nationality Address Mobile No. Email Id
No
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Lalchandani Kunal PATEL INSTITUTE
1 Indian 9727281868 kunal.140410119037@gmail.com
Nanak OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Bhagat Akshay PATEL INSTITUTE
2 Indian 7043131157 akshay.140410119006@gmail.com
Tolaram OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Dayama Zukhruf PATEL INSTITUTE
3 Indian 9173447279 zukhruf.140410119017@gmail.com
Atiq OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
4 Patel Paurav Kunal Indian Mechanical 9537554577 paurav.140410119090@gmail.com
Engineering ,
SARDAR
VALLABHBHAI
PATEL INSTITUTE
OF TECHNOLOGY,
VASAD ,
2/6
12/04/2018 PDE Details

Gujarat
Technologycal
University.
Mechanical
Engineering ,
SARDAR
VALLABHBHAI
Chawla Avinash PATEL INSTITUTE
5 Indian 7048638631 avinash.140410119015@gmail.com
Jagdish OF TECHNOLOGY,
VASAD ,
Gujarat
Technologycal
University.
I/We, the applicant(s) hereby declare(s) that:

Following are the attachments with the applications :

Form 2 - PROVISIONAL/COMPLETE SPECIFICATION

1 . Title of the project/invention :
Parametric analysis on tool shape for SPIF(Single Point Incremental Forming)
2. Preamble to the description :
Provisional
3. Description
a) Field of Project / Invention / Application :
The present invention relates, in general, to an improvement of the Incremental Sheet Metal Forming
technology for easier and more accurately forming of sheet material of various composition. Single Point
Incremental Forming (SPIF) is a forming process which depresses the sheet of metal by tracing a single point
tool in a downward path. The effectiveness of the ISF process is mainly evaluated based on the process outputs
like formability, surface quality, geometric accuracy, deformation limits, forming time, etc. Through a brief
review of the effect of process parameters on the outcome of the incremental sheet metal forming process, it is
evident that the optimisation of tool shapes can greatly improve the process.
b) Prior Art / Background of the Project / Invention :
Incremental sheet forming (ISF) is a sheet metal forming technique where a sheet is formed into the final work
piece by a series of small incremental deformations. Generally, the sheet is formed by a round tipped tool,
typically 5 to 20 mm in diameter. The tool, which can be attached to a CNC machine, a robot arm or similar,
indents into the sheet by about 1 to 5 mm and follows a contour for the desired part. It then indents further and
draws the next contour for the part into the sheet and continues to do this until the full part is formed. The ISF
process is generally implemented by clamping a sheet in the XY plane, which is free to move along the Z axis.
The tool moves in the XY plane and is coordinated with movements in the Z axis to create the desired part. It
is often convenient to retrofit a CNC milling machine to accommodate the process. Hemispherical, flat-
bottomed and angular tool profiles can be used to achieve differing surface finishes and forming limits.
c) Summary of the Project / Invention :
The major elements of ISF are identified as follows: (i) a sheet metal blank, (ii) a blank holder, (iii) a single-
point forming tool and (iv) CNC machine. The path of the tool is responsible for the shape, size and accuracy
of the final product. AA8011 sheets of 1 mm thickness which were cut to a size of 350 mm × 350 mm were
used for the experiment work. The sheets were then annealed. A CNC controller having capability for
controlling individual 3 axes is used to control the movements of the tool. The experiments were performed at
3/6
12/04/2018 PDE Details

Micro Tech Engineering on BFW Chakra 3-axis Vertical Machining Center. The tool path needs to be
optimized and a free run is taken before performing the actual manufacturing on the sheet metal in order to
ensure the proper functioning of the machine. The tool path which we considered in our project is Spiral Path.
A sheet of metal is deformed by progressive and localized plastic deformation using three different tool shapes
and this path of the tool is controlled by a CNC machine. The tool moves over the surface of the sheet and
results the final shape. The forming tool with three different shapes namely Hemispherical, Angular and Flat at
bottom end and 10 mm diameter was made of WPS steel and later hardened. The sheet metal was fixed and
positioned with the upper blank holder (pressure plate), which was pressed onto the lower blank holder. The
whole support tool was inserted and fixed onto the worktable of the milling machine. Lubrication is needed to
ensure the desired surface quality and prevent sheet or tool failure. We have used two lubricants in our project:
Machine Oil (HP Enklo 68) and Engine Oil (Castor 20W-/4T). The incremental step-down size (step size, ?z)
affects the machine time and the surface quality which is in our case is kept as 0.3 mm. Feed rate is the speed
with which the forming tool moves around the mill bed and it is kept as 2000mm/min. The spindle speed is the
rotation speed at which the tool rotates and its values is set as 2000 rpm in the CNC milling machine along
with the CAM software. Once the machine starts, the forming tool spins and follow the trajectories to obtain
the desired part. Then the part can be used without any additional process. Tests were conducted on using
different tool shapes namely Flat, Angular and Hemispherical while keeping the experimental parameters
constant which includes spindle speeds, step depth, feed rates and the tool radii. Our objective is to analyse
how variation in various parameters of tool shape affects the forming characteristics of SPIF so that maximum
surface finish and accuracy is achieved in the process.
d) Objects of Project / Invention :
The Main objective of this work is to perform experiments to determine the surface finish, shape accuracy,
thickness distribution and effect of lubricants with the help of given tool shapes namely Flat, Angular and
Hemispherical in relation with four common SPIF forming parameters: step size, angle, spindle speed, and
feed rate. The results obtained should be able to predict and categorize the extent of the thickness reduction
occurring before fracture along with the wall angle at which fracture initiated. The second objective of this
study is to determine the shape accuracy of the manufactured parts in terms of depth achieved, thickness
reduction and wall angles achieved in relation to the CAD file. Tests were conducted on using different tool
shapes namely Flat, Angular and Hemispherical while keeping the experimental parameters constant which
included spindle speeds, step depth, feed rates and the tool radii in order to study the amount of deviation that
different tool shapes show by comparing the surface finish, forming time, lubricant used and shape accuracy.
e) Drawings :
17218_Drawing1.jpg
17218_Drawing2.jpg
17218_Drawing3.jpg
17218_Drawing4.jpg
17218_Drawing5.jpg
f) Description of Project / Invention : (full detail of project) :
Incremental forming is the process of forming sheet metal into complicated shapes without the use of
dedicated dies. The method uses a single point tool which plastically deforms sheet metal, which is clamped in
a fixture to provide a localised deformation. The final shape of the part can for instance be obtained by the
relative movement of a forming tool with respect to the fixture. By incrementally moving the forming tool
over the sheet using a controllable positioning system, for instance a computer numerically controlled tool, the
plastically deformed points are, in effect, added as a means to move and provide a final shape. Single point
incremental forming (SPIF) of metal sheets is a new technology, flexible process that allows manufacturing
sheet metal components without the need for expensive, dedicated dies. SPIF needs only a simple rig,
positioned on the worktable of a CNC machine, to clamp the metal sheet, and a small tool whose movement is
controlled according to fixed paths. The SPIF process is very suitable for rapid prototypes and small series
production but due to its characteristic of point-to-point forming it is quite slow and it cannot be used for mass
production. The effectiveness of the ISF process is mainly evaluated based on the process outputs like
formability, surface quality, geometric accuracy, deformation limits, and the forming time.
4/6
12/04/2018 PDE Details

Thus, there is a need in the art for improving the methods of incremental forming. Through a brief review of
the effect of process parameters on the outcome of the incremental sheet metal forming process, it is evident
that the optimisation of tool shapes can greatly improve the process. The effect of these different tool shapes
strategies on the thickness distribution, surface quality and forming time will then be investigated.
g) Examples :
h) Claims (Not required for Provisional Application) / Unique Features of Project
The incremental forming process relies strongly on automation and digitisation. In the basic process setup, the
desired part is modelled using CAD-software. The CAD model then serves as the basis to create the forming
trajectory using CAM-software. The forming trajectory requires further post-processing to suit the needs and
specifications of the forming platform. Finally, in idealised conditions the desired part is formed from a
clamped piece of sheet metal without the need for additional support tooling.
4. Claims
5. Date and signature
6. Abstract of the project / invention :
Sheet Metal forming is a crucial method of modern manufacturing. Current technique of sheet metal forming
involves usage of a separate die for forming which makes the process expensive as well as time consuming for
manufacturing special purpose goods. Single Point Incremental Forming (SPIF) is a forming process which
depresses the sheet of metal by tracing a single point tool in a downward path. Our objective is to analyse how
variation in various parameters of tool shape affects the forming characteristics of SPIF so that maximum
surface finish and accuracy is achieved in the process.

Form 3 – STATEMENT AND UNDERTAKING UNDER SECTION 8

I/We, Lalchandani Kunal Nanak ,Bhagat Akshay Tolaram ,Dayama Zukhruf
Name of the applicant(s) :
Atiq ,Patel Paurav Kunal ,Chawla Avinash Jagdish
Hereby declare :

Name,Address and Nationality (i) that I/We have not made any application for the same/substantially the
of the joint applicant : same victim invention outside India.

(ii) that the rights in the application(s) has/have been assigned to

Name of the Date of Application Status of the Date of Date of
Country Application Number Application Publication Grant
N/A N/A N/A N/A N/A N/A

(iii)That I/We undertake that upto the date of grant of the patent by the
Controller, I/We would keep him informed in writing the details regarding
corresponding applications for patents filed outside India within three
months from the date of filing of such application.
Dated this 12 day of April 2018
To be signed by the applicant or
his authorised registered patent Signature.................
agent :
Name of the Natural Person who Lalchandani Kunal Nanak ,Bhagat Akshay Tolaram ,Dayama Zukhruf Atiq
has signed : ,Patel Paurav Kunal ,Chawla Avinash Jagdish
To,
The Controller of Patents,
5/6
12/04/2018 PDE Details

The Patent Office,

At Mumbai

6/6