Tool path generation for single point incremental forming using intelligent sequencing and multi-step mesh morphing techniques

A new methodology of generating optimized tool paths for incremental sheet forming is proposed in this work. The objective is to make parts with improved accuracy. To enable this, a systematic, automated technique of creating intermediate shapes using a morph mapping strategy is developed. This strategy is based on starting with a shape different from the final shape, available as a triangulated STL model, and using step-wise incremental deformation to the original mesh to arrive at the final part shape. Further, optimized tool path generation requires intelligent sequencing of partial tool paths that may be applied specifically to certain features on the part. The sequencing procedure is discussed next and case studies showing the application of the integrated technique are illustrated. The accuracy of the formed parts significantly improves using this integrated technique. The maximum deviations are brought down to less than 1 mm, while average absolute deviations of less than 0.5 mm are recorded

Effect of stress relieving heat treatment on surface topography and dimensional accuracy of incrementally formed grade 1 titanium sheet parts

The forming of parts with an optimized surface roughness and high dimensional accuracy is important in many applications of incremental sheet forming (ISF). To realize this, the effect of stress relieving heat treatment of grade-1 Ti parts performed before and after forming on the surface finish and dimensional accuracy was studied. It was found that heat treatment at a temperature of 540 °C for 2 h improves the surface finish of formed parts resulting in a surface with little or no visible tool marks. Additionally, it improves the dimensional accuracy of parts after unclamping from the rig used for forming, in particular, that of parts with shallow wall angles (typically <25°). It was also noted that post-forming heat treatment improves the surface finish of parts. The surface topography of formed parts was studied using interferometry to yield areal surface roughness parameters and subsequently using secondary electron imaging. Back-scatter electron microscopy imaging results coupled with energy-dispersive X-ray (EDX) analysis showed that heat treatment prior to forming leads to tool wear as indicated by the presence of Fe in samples. Furthermore, post-forming heat treatment prevents curling up of formed parts due to compressive stresses if the formed part is trimmed

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Single point incremental forming (SPIF) is a relatively new manufacturing process that has been recently used to form medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. Prior work on accuracy characterization has shown that feature behavior is important in predicting accuracy. In this study, a set of basic geometric shapes consisting of ruled and freeform features were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions using multivariate adaptive regression splines (MARS) are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, distance to feature borders, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case where the curvatures in the part lie between that of ruled features and freeform features. It is shown that a mixed-MARS response surface model using a weighted average of the ruled and freeform surface models can be used for such a case to improve the mean prediction accuracy within ±0.5 mm. The predicted deviations show a reasonable match with the actual formed shape for the implant case and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants

Evaluation of strain and stress states in the single point incremental forming process

Single point incremental forming (SPIF) is a promising manufacturing process suitable for small batch production. Furthermore, the material formability is enhanced in comparison with the conventional sheet metal forming processes, resulting from the small plastic zone and the incremental nature. Nevertheless, the further development of the SPIF process requires the full understanding of the material deformation mechanism, which is of great importance for the effective process optimization. In this study, a comprehensive finite element model has been developed to analyse the state of strain and stress in the vicinity of the contact area, where the plastic deformation increases by means of the forming tool action. The numerical model is firstly validated with experimental results from a simple truncated cone of AA7075-O aluminium alloy, namely, the forming force evolution, the final thickness and the plastic strain distributions. In order to evaluate accurately the through-thickness gradients, the blank is modelled with solid finite elements. The small contact area between the forming tool and the sheet produces a negative mean stress under the tool, postponing the ductile fracture occurrence. On the other hand, the residual stresses in both circumferential and meridional directions are positive in the inner skin of the cone and negative in the outer skin. They arise predominantly along the circumferential direction due to the geometrical restrictions in this direction.The authors would like to gratefully acknowledge the financial support from the Portuguese Foundation for Science and Technology (FCT) under project PTDC/EMS-TEC/1805/2012. The first author is also grateful to the FCT for the postdoctoral grant SFRH/BPD/101334/2014.info:eu-repo/semantics/publishedVersio

Modelling and Verification of Energy Consumption in CNC Milling

Electrical energy consumption forms 99% of the environmental impact of machining operations. Whilst replacing existing machineries for more energy efficient ones does not deem possible in short term, process planning for machining with energy consumption in mind is a more accessible solution. The effect of cutting parameters on power consumption in CNC milling of 6082 T6 aluminum alloy was investigated in this paper. Mathematical models were developed to estimate the energy and power consumption in CNC milling machines. The analysis indicated that the two less studied parameters of axial and radial depth of cut have significant impact on the total energy consumption of machining processes. Increased axial and radial depth of cut not only increase material removal rate but also increase the portion of machine tool’s power consumption dedicated to material cutting. This study indicated that 82% reduction in energy consumption can be achieved through precise selection of cuttingparameters.<br/

An efficient method for thickness prediction in multi-pass incremental sheet forming

Incremental sheet forming (ISF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. In the ISF process, efficient and accurate prediction of part thickness variation is still a challenging task, which is especially true for the multi-pass ISF process. The Sine law equation and the finite element method (FEM) are the two commonly used conventional prediction methods. However, these approaches are either with limited accuracy or very time consuming. For the multi-pass ISF process, the thickness prediction is even more challenging since two or more forming steps are involved. Focusing on the thickness prediction of multi-stage ISF process, this work proposes a thickness prediction model based on the geometrical calculation of intermediate shapes of the formed part and backward tracing of nodal points of the forming tool. By developing this method, the thickness distribution can be calculated through the predicted nodal displacement in the ISF process. To verify the proposed model, four different geometrical shapes, i.e., conic, parabolic conic, non-axisymmetric, and hemispherical parts, are physically formed by using a NC ISF machine. The geometric shapes and the detailed thickness distributions of the formed parts are carefully measured and compared with the prediction model developed. Good agreements between the analytical predictions, and the experimental results are obtained. This indicates the effectiveness and robustness of the developed thickness prediction approach

Titanium based cranial reconstruction using incremental sheet forming

In this paper, we report recent work in cranial plate manufacturing using incremental sheet forming (ISF) process. With a typical cranial shape, the ISF process was used to manufacture the titanium cranial shape by using different ISF tooling solutions with and without backing plates. Detailed evaluation of the ISF process including material deformation and thinning, geometric accuracy and surface finish was conducted by using a combination of experimental testing and Finite Element (FE) simulation. The results show that satisfactory cranial shape can be achieved with sufficient accuracy and surface finish by using a feature based tool path generation method and new ISF tooling design. The results also demonstrate that the ISF based cranial reconstruction has the potential to achieve considerable lead time reduction as compared to conventional methods for cranial plate manufacturing. This outcome indicates that there is a potential for the ISF process to achieve technological advances and economic benefits as well as improvement to quality of life

Comparative LCA technology improvement opportunities for a 1.5 MW wind turbine in the context of an offshore wind farm

Wind energy is playing an increasingly important role in the development of cleaner and more efficient energy technologies leading to projections in reliability and performance of future wind turbine designs. This paper presents life cycle assessment (LCA) results of design variations for a 1.5 MW wind turbine due to the potential for advances in technology to improve the performance of a 1.5 MW wind turbine. Five LCAs have been conducted for design variants of a 1.5 MW wind turbine. The objective is to evaluate potential environmental impacts per kilowatt hour of electricity generated for a 114 MW onshore wind farm. Results for the baseline turbine show that higher contributions to impacts were obtained in the categories Ozone Depletion Potential, Marine Aquatic Eco-toxicity Potential, Human Toxicity Potential and Terrestrial Eco-toxicity Potential compared to Technology Improvement Opportunities (TIOs) 1 to 4. Compared to the baseline turbine, TIO 1 showed increased impact contributions to Abiotic Depletion Potential, Acidification Potential, Eutrophication Potential, Global Warming Potential and Photochemical Ozone Creation Potential, and TIO 2 showed an increase in contributions to Abiotic Depletion Potential, Acidification Potential and Global Warming Potential. Additionally, lower contributions to all the environmental categories were observed for TIO 3 while increased contributions towards Abiotic Depletion Potential and Global Warming Potential were noted for TIO 4. A comparative LCA study of wind turbine design variations for a particular power rating has not been explored in the literature. This study presents new insight into the environmental implications related with projected wind turbine design advancements

Lifecycle scenario design for product end-of-life strategy

This paper proposes a method for supporting the design of product lifecycles. The main approach involves supporting designers in determining a lifecycle strategy by describing lifecycle scenarios at an early stage of lifecycle design. The authors define a representational scheme for the lifecycle scenario and outline a support system based on the idea of the Cognitive Design Process model allowing the designers to examine various possibilities of lifecycle strategy. A number of alternative scenarios are managed by the Truth Maintenance System implemented in this approach. Finally, in order to embody the strategy in the later stages, the system derives requirements for product and process design. This paper outlines the lifecycle scenario of a cellular phone as a case study, which indicates the system's suitability for computer-aided description of scenarios and its facilitation of lifecycle strategy development

Review on the influence of process parameters in incremental sheet forming

Incremental sheet forming (ISF) is a relatively new flexible forming process. ISF has excellent adaptability to conventional milling machines and requires minimum use of complex tooling, dies and forming press, which makes the process cost-effective and easy to automate for various applications. In the past two decades, extensive research on ISF has resulted in significant advances being made in fundamental understanding and development of new processing and tooling solutions. However, ISF has yet to be fully implemented to mainstream high-value manufacturing industries due to a number of technical challenges, all of which are directly related to ISF process parameters. This paper aims to provide a detailed review of the current state-of-the-art of ISF processes in terms of its technological capabilities and specific limitations with discussions on the ISF process parameters and their effects on ISF processes. Particular attention is given to the ISF process parameters on the formability, deformation and failure mechanics, springback and accuracy and surface roughness. This leads to a number of recommendations that are considered essential for future research effort