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RP of Sheet Metal using Single Point Incremental Forming[SPIF]
BY
SUDHEER KUMAR
SAI KIRAN
1
CONTENTS
Introduction
SPIF process configurations
Tool path strategies
Adaptive Slicing
Applications
Conclusions
2
RP as an ADDITIVE MANUFACTURING 3
Incremental Sheet Metal Forming[ISMF]
Features
Localised deformation
Increased Formability
Flexible to form complex geometrical shapes
4
SPIF process configuration
Negative forming process Positive forming process
a) Without Die
b) With Die
a) Using partial support
b) Using full support
5
Negative ISMF process
Where the tool moves in negative Z direction
in incremental steps
6
Positive ISMF process
Where a rigid member
support from the bottom
7
Other Variants of ISMF processes
Two point incremental sheet metal forming
8
Other Variants of ISMF processes 9
Tool Path Strategies 10
Tool Path generation
3 tool path generation methods are presented here.
i) Horizontal slicing
ii) Inclined Slicing
iii) Offset method
Tool path always generated starting from outer loop of feature
11
Horizontal Slicing
suitable for features with horizontal inner and outer loops.Constant slicing height(∆z) is used
12
Inclined slicing
Slicing features with non-parallel outer and inner loops
Planes rotating about an axis are used for slicing
Axis of rotation is intersection of outer loop plane and inner loop plane
Slice thickness is not constant
13
Offset method
Tool path for features which can not be sliced because of height smaller than slicing height.
Outer and inner loops are joined with straight lines as shown.
Equal number of equidistant points are generated on each line.
14
Slicing Strategies 15
Cup with inclined hump model 16
Forming sequence 17
Different geometrical shapes formed by ISMF
18
Applications
Conical geometrical part
19
Applications 20
Applications 21
Applications 22
Applications
Complex automotive parts. Amino KK. Japanese company
23
Applications 24
Conclusions
ISMF does not require dies. So changes in the design can be easily and economically incorporated .
Adaptive slicing is possible to attain higher accuracies in the part.
Formability in ISMF is much higher than that of traditional forming processes, and there by complex geometries can be made.
ISMF process is relatively new and emerging field and research need to be done for improving the accuracy and calculation of specific forces required.
25
Thank You
26