Metal forming Course

Incremental sheet metal Forming

single Point Incremental Forming

Compiled By:
Houshang Ansari kajal
Hassan kargar Pishbijari
Hassan Yousefinezhad Gildeh
MS.C Students Of Manufacturing & Production
lecturer :
Dr.M.bakhshi
Babol Industrial University
www.nit.ac.ir
Dec.2012 1/31
 Contents:
1- Abstract
2- Introduction
3- Methods
4- Characteristics
5- Applications
6- Tools & Equipments
7- Advantages & disadvantages
8- Conclusion
9- Suggestion
10- Research & Developments
11- Acknowledgments
12- References
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Abstract
During the last decade, incremental forming is an innovative
processing method which has been strongly investigated. Its potential
as a flexible manufacturing method was noticed.

Incremental sheet forming is a method , where a spherical

numerically controlled tool is used to push the sheet to the desired
shape against a simple support tool.

keywords: Incremental sheet forming , Die less Forming ,

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Introduction
In the manufacturing world of today , the
demand of highly customized is increasing every
day . Even if the mass production is still used, the
small quantity batches are more and more
required. The key words of manufacturing are:
Flexibility , product customization, Customer
Orientation , high quality , low production cost.

In sheet metal forming techniques

, several evolution has made big steps
in the last period of time:

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Steps in sheet metal forming

1-Conventional Deep Drawing

2-NC control for stamping & bending

3-Hydroforming.

4-Multi-point tools

5-Incremental Sheet forming (ISF)

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Conventional Deep Drawing

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CNC control for stamping & bending

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Hydroforming.

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Multi-point tools

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Incremental Sheet forming (ISF)

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History of ISF
Variations of ISF have long been practiced in small workshops and
private enterprises , and some early concepts of ISF were patented:
1- In the USA by Roux (1960) and Leszak(1967).
2- Academic research bean in the early 1990 in Japan
3- Recently has attracted increasing interest in Europe and Canada.
SPIF & TPIF
4- SPIF of circular and elliptical by Iseki et al (1993)
5- Used FE analysis to strains by Shim and park (2001)
6- Moving back and forth along a straight line by Kim and park (2002)
7- Pyramids formed by SPIF and TPIF byBambach et al (2003)
8- Cone formed byFratini et al(2004)
8- A comprehensive review of the development of the process is given
by Jeswiet et al (2005)

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Method's

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Method's  Spinning

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Method's  Single-point

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Method's  Two-point

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Method's -> SPIF & TPIF

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Characteristic's

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Forming Step & Tool patch

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Forming Step & Tool patch

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Application’s

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Application’s

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 Forming Parameters

d: Tool diameter
t.: Sheet thickness
α: Tool direction angle
S: Spindle rpm
f: Federate Return
∆z: Step movment
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Tools & equipment’s

Forming Tool

Hexapod machine

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Tools & equipment’s

RoBoShaping

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Advantages & disadvantages
Advantages :
1- The advantage of utilizing a conventional CNC milling machine.
2- Increase in materials formability due to the nature of the process.
3- The great flexibility derived from the absence of positive or negative dies.
4- Easley in re-setup of equipment's for part changing.
5- forming forces is too small than Deep Drawing forces.

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Advantages & disadvantages

Disadvantages:
1- Spring Back.

2- Sheet fracture under Tool 3- deformation and Un-like form

Pressure and friction.

4- forming time is too large than deep drawing time.

5- In negative forming ,it’s difficult to form sharp corner & edge
because crack easily occur.
6- Deformation and Un-Like form sometimes occur.

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Conclusion

1- Increase in sheet thickness Increase in strain Increase in formability.

2- Increase in Tool diameter decrease in stress decrease in formability.

3- Increase in Tool Federate Increase in stress decrease in formability.

4- Increase in Tool speed Increase in heat Increase in formability.

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Suggestion’s

With discussed characteristic's and flexibility of ISF(SPIF & TPIF)

We suggestion’s to provide research for following further
application :

1-Use of ISF to forming thermoplastics sheet.

2- Use of ISF to car body smoothing.

3- Deliberation of pre-heat effect on formability.

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 Research & Developments

Macro Incremental Forming

the main focus of our work has been on application-oriented research and
development in the field of production technology for the automotive and Return
mechanical engineering sectors.
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Acknowledgments

With special thanks to:

Professors of Metal forming - Babol Industrial University

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References
1- Jong-Jin park , Yung-ho Kim, “Fundamental studies on incremental sheet metal forming
technique” , Journal of Materials processing Technology 140 (2003) 447-453.
2- “Incremental sheet metal forming : a die –less rapid prototyping process for sheet metal” , IMRC
(manufacturing Process and systems Research project), University of BATH.
3- Crina Radu ,” Effect of process parameters on the quality of parts processed by single point
incremental forming”, International journal of modern manufacturing technologeis , vol.III.No.2/2011.
4- Alexandru C.FILIP , Ion NEAGOE,”An overview on incremental sheet forming , a method for rapid
manufacturing of hollow metal parts", Academic journal of manufacturing engineering , vol.8,issue
3/2010.
5- M Skjoedt , M B Silva , P A F martins , N Bay , “ strategies and limits in multi-stage single-point
incremental forming", technical university of Denmark, department of mechanical engineering,
kongens lyngby, Denmark, strain Analysis vol.45.
6-W.C.Emmens , D.H.Van , A.H.Van,” The FLC , enhanced formability , and incremental sheet
forming”,International Deep drawing research group.IDDRG 2009 int.Conference.Golden.Co.USA.
7- A.petek,K.kuzman,J.Kopac,”Deformation and forces analysis of single point incremental sheet
metal forming”,International scintific journal , vol.35.issue 2.feb 2009.
8- Kathryn jackson,Julian Allwood ,”The mechanics of incremental sheet forming”,Department of
engineering,University of cambridge,Journal of materials processing technology 209(2009,1158-1174)
‫محسن یوسفی جدیدی ؛ عبدالحسین جاللی آقچای ؛ داریوش جواب ور ؛» بررسی تئوری و تجربی‬-9
‫ همایش ملی مهندسی‬،»‫تاثیر پارامترهای فرایند بر میزان شکل پذیری ورق در فرآیند شکل دهی تدریجی‬
.1391 ‫ مهرماه‬، ‫ دانشگاه آزاد اسالمی واحد الیگودرز‬،NCME2010‫مکانیک‬
‫»بهبود عیوب فرم دهی ورق فلزی در فرایند شکل دهی‬، ‫ عباس وفایی صفت‬، ‫وحید ریخته گر نظامی‬- 10
‫ اسفندماه‬، ICME 2010 ‫ دهمین کنفرانس مهندسی ساخت و تولید ایران‬، « ‫چند نقطه ای ورقهای فلزی‬
.‫ دانشگاه صنعتی نوشیروانی بابل‬1388
‫”بررسی تئوری و تجربی تاثیر سرعت دورانی در فرآیند شگل دهی‬، ‫ مهدی وحدتی‬، ‫علیرضا وحدتی‬-11
‫ دانشگاه‬،‫دهمین کنفرانس مهندسی ساخت و تولید ایران‬،”‫تدریحی ورق فلزی بر روی ماشین تراش‬
1388 ‫صنعتی بابل اسفند‬

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