Session: 02-07-01: Advanced Material Forming, Friction Stir Welding, and Deformation

Paper Number: 69895

Start Time: Thursday, 12:40 PM

69895 - Residual Formability of Single Point Incrementally Formed Part 

A sudden increase in the usage of automotive vehicles results in sudden increases in the fuel consumption which results in an increase in air pollution. To cope up with this challenge federal government is implying the stricter environmental regulation to decrease air pollution. To save from the environmental regulation penalty vehicle industry is researching innovation which would reduce vehicle weight and decrease the fuel consumption. Thus, the innovation related to light-weighting is not only an option anymore but became a mandatory necessity to decrease fuel consumption. To achieve this target, the industry has been looking at many innovative manufacturing processes like electric assisted manufacturing, hydroforming, high speed forming and many. All these innovative process promises more uniform deformation and increase formability in the part as compared to the conventional sheet metal forming process. One such process is single point incremental forming. Single point incremental forming is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. The process is very similar to spinning process where the part needs to spin, and a roller deforms the single point during rotation of the part while feeding forward to deform the geometry in a desired shape. In spinning process two parameters should have been in synchronization i.e., the revolution of the part per minute and the feed of the roller. In contrast in single point incremental forming the part stays fixed and the tool pin makes the planar and downward motion to shape the part. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but research on residual formability after single point incremental forming was limited. The previously published paper in IMECE2019 by the author studied the residual formability of single point incrementally formed part with four cone angles. It was found that the 30 and 45^o cone angle did not survive during single point incremental forming but 60 and 90^o did.  Further 60 and 90^o cones were conventionally restrike with spherical dome punch to determine the residual formability, however the 60^o cone failed intermediately, but 90^o deformed to full shape of dome and then fractured. In this paper the aim is to construct the whole section of forming limit point from uniaxial to equal-biaxial deformation mode restrike and measure the forming limits. These points will construct the whole residual forming limit curve of a single point incrementally formed part.

Presenting Author: Chetan P. Nikhare The Pennsylvania State University

Authors:

Chetan P. Nikhare Penn State Erie - Behrend College