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Single point and asymmetric incremental forming

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Abstract

This paper presents an update on single point incremental forming (SPIF) of sheet metal since 2005. It includes a description of the process with new information on the maximum forming angle, \(\phi_{ \hbox{max} }\), for 5052-H32. An in-depth example of the successful design and production of parts is given for industry. This includes discussion on production times and surface roughness with details that will help designers. A general design guide for users of SPIF is provided. It is based upon experience gained in the last decade. In general, materials show a trend of decreasing formability with increasing initial thickness. It is shown that for thicker sheet metal, it is recommended using large spherical tools (12.7 mm or larger), or a large flat-ended tool. The flat-ended tool provides the best combination of good formability and very low surface roughness. For aluminum, galvanized steel and stainless steel, it is recommended using a flat-ended tool. Advances in multi-pass techniques and information on successful and useful numerical models which predict forming behaviour are included. Finally, there is a discussion on future work needed in SPIF.

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Abbreviations

z :

vertical step size between forming passes

ϕ :

wall angle

ϕ max :

maximum wall angle

d :

tool diameter

r :

tool radius

R :

radius of test shape wall angle increase

L :

overall depth of the part

H :

vertical height of the tool centre above the bottom of the test shape

h :

vertical height of the point of contact between the tool and test surface

\(\delta_{\phi }^{ \pm }\) :

error bounds in wall angle

\(t_{\text{i}}\) :

initial sheet thickness

\(t_{\text{f}}\) :

final sheet thickness

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Acknowledgements

The authors thank NSERC and Auto 21 for their support.

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Authors and Affiliations

  1. Department of Mechanical and Materials Engineering, Queen’s University, Kingston, ON, Canada

    J. Jeswiet & P. Gupta

  2. Faculty of Engineering and Information Technology, Australian National University, Canberra, Australia

    D. Adams, M. Doolan & T. McAnulty

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  1. J. Jeswiet
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  2. D. Adams
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  3. M. Doolan
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  4. T. McAnulty
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  5. P. Gupta
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Correspondence to J. Jeswiet.

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Jeswiet, J., Adams, D., Doolan, M. et al. Single point and asymmetric incremental forming. Adv. Manuf. 3, 253–262 (2015). https://doi.org/10.1007/s40436-015-0126-1

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