MFG-356

Multiple Sheet Single Point Incremental Forming For Dual

Phase Steel Sheet
K. A. Selvarajan*, C. Sathiya Narayanan

Department of Production Engineering, National Institute of Technology,

Tiruchirappalli, Tamil Nadu
*Corresponding author: ka_selvarajan@yahoo.co.in

Abstract 3. Single point Tool with ball, spare

balls
For mass production of sheet metal
components, press tools with punch and 4. Sheet size 150mm x150 mm
dies are used conventionally. However, for 5. Grid marking in sheets
batch production and rapid prototyping, 6. CNC program
making of punch and dies are not
7. CAD values
advisable in terms of cost and time factors.
Single point Incremental Forming (SPIF) 8. CNC operator
method is used to overcome these 9. Lubricant
problems. A lot of experiments are being 10. Grease
conducted all over the world in industrial
academic and research institutions for the SPIF Advantages Many shapes from single
Fixture
past few decades on SPIF. For fine tuning
the SPIF process for improvement in
productivity and accuracy, various ideas
are being proposed and experiments are
being carried out day by day. In this work,
one of such ideas that are Multiple Sheet
Single Point Incremental Forming
(MSSPIF) Method is followed for forming
dual phase steel sheet. The limiting strain
measured by conducting straight groove is
found to be good. The Forming Limit
Diagram for the same sheet also is drawn.
Keywords: MSSPIF; FLD; Dual phase
steel
1. Introduction
Single point Incremental Forming
Single point Incremental forming of sheet Special Fixture for conducting SPIF
metal is a die-less flexible forming process
that locally deforms sheet metal using a
moving tool head achieving higher forming
limits than conventional processes.
Essential Requirements for SPIF in general
1. CNC Vertical Machining Center
2. Special Fixture for conducting SPIF
Recent Development in SPIF Invention of MPIF Tool (Patent Protected) [1]

Recent Development in SPIF Invention of MPIF Tool (Patent Protected) [ 1 ]

2. Summary of Features Coined from
previous prototypes to Modified final
Prototype [4]
Guiding principles prepared by Three
inventors
1. Full freedom for designing parts,
assembly, working mechanism and giving
dimensions
2. Tool should work and fulfil all the
requirements
3. Tool should accommodate
minimum one ball and more than one ball
4. Balls should rotate freely
5. Balls only should touch the job.
Tool parts should not touch or foul the job
6. When balls only touch the job, there
should be some side clearance & bottom
clearance between tool parts and job
7. Balls should not go inside during or
after incremental forming operation
8. Balls should not come outside
during or after incremental forming
operation
9. Design for Safety in all aspects
(Job, Tool ,Fixture, CNC Machine
,Operator)
10. Design for existing fixture size and
required specimen plate size (calculate
optimum tools size)
11. Design for accommodate various
size balls
12. Design for check the first job.
Calculate the Tool compensation value to
use in CNC program
13. Design for check the productivity
improvement for various shapes of jobs.
14. Design for Usability (User Manual)
and list out some instructions to avoid tool
damage.
15. Summarise all the FAQ Frequently
Asked Questions & Answers by inventors Experimental Details DP 600 Sample
(User Manual). preparation and Microstructure
DP steel Introduction
Proposed Approach
• Researches on incremental forming
of multiple sheets of duel phase steel are
not conducted earlier. Because it is a new
process
• Multiple Sheet Single Point
Incremental Forming (MSSPIF) With 2,3,4
Sheets for Dual Phase Steel Sheet.DP 600
• Maximum number of Dual Phase
(DP) steel sheet can be formed in a single
set up.
• Expected Productivity will be
increase in 2 times or 3 times or 4 times.
Experimental Details
1. DP 600 Steel sheet Purchased and
cut for size 150mm x150mm
2. Sample Preparation for Micro
Structure at NIT Trichy Lab
3. Circular Grid Laser Marking on
sheets at Nano Markers Srirangam Trichy
4. MSSPIF conducted at CNC Vanitha
Molding Thuvakudi Trichy
5. Straight Groove Test Conducted
With 2 , 3 ,4 sheets
6. Deformation Measured and
Tabulated 2 , 3 ,4 sheets at Nano Markers
Srirangam Trichy
7. FLD Drawn for 2 , 3 ,4 sheets in
consolidated form
8. Multi Point Incremental Forming
Tool invented for further research and
patent protected
Experimental Details
Straight groove Test - ( Multi Sheets )
Straight groove Test Results
Readings – Sheets (1,2) (3,4,5)

Straight groove Test

Readings - Sheets (6,7,8,9)

3. Results and Discussion

Straight groove Test - (Multi Sheet)
Formability Limit Diagram (FLD) Calculations Illustration

Conventional Formability Limit Diagram (FLD)

4. Conclusions • DP 600 Steel sheets grid engraved.
• DP 600 Steel sheets cut to required • DP 600 Steel Sample Prepared and
size 150mm by 150 mm conformed the micro structure.
 • Straight Groove Test Conducted
With 2 , 3 ,4 sheets
• The limiting strain measured by
conducting straight groove is found to be
good.
• The Forming Limit Diagram for the
same sheet also is drawn.
• Many experiments need to be
conducted in this area since this process
can be used for batch production.
• Multi Point Incremental Forming
Tool invented for further research and
patent protected
References
[1] K .A.Selvarajan, Dr C Sathiya
Narayanan, Dr C Raju, Design and
development of Multi point incremental
forming tool with 6 balls of
8mm/10mm/12mm/12.7mm [0.5inch].
Indian IPR Journal dated 19-05-2017 page
no 15858 .Govt of India Gazette.
[2] K.A.Selvarajan, AMIE, Lecture on Multi
Point Incremental Forming Tool The
institution of engineers[India]
Tiruchirappalli local centre on 17-01-2018
circular dated 12-01-2018
[3] K A Selvarajan et al Development of
Database for Literature Review on Multi
Point Incremental Forming Tools ( Patent
Protected) AMPIE’18 Book of Abstract
page International conference at
Department of Mechanical Engineering at
Mahindra institute of Engineering
Technology Namakkal Tamilnadu on 14-15
February 2018
[4] 4. K A Selvarajan et al Development
of Multi Point Incremental Forming Tools (
Patent Protected) – An overview from
starting stage prototypes AMPIE’18 Book
of Abstract page International conference
at Department of Mechanical Engineering
at Mahindra institute of Engineering
Technology Namakkal Tamilnadu on 14-15
February 2018
[5] K A Selvarajan et al Co efficient of
Performance between Single and Multi
Point Incremental Forming Tools ( Patent
Protected) – for Similar Components
AMPIE’18 Book of Abstract page
International conference at Department of
Mechanical Engineering at Mahindra
institute of Engineering Technology
Namakkal Tamilnadu on 14-15 February
2018
[6] K A Selvarajan et al Experimental
evaluation of Formability and Fracture
Mechanics of Titanium grade 2 sheet in
Multi Point Incremental Forming for
submitting mini project for M.Tech in the
Department of Manufacturing and
Automation College of Engineering
Trivandrum Kerala state. April 2018
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Point Incremental Forming For Dual Phase
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[13] Radhika Thangavelu et al Single
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