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Feasibility Study of the SPIF Process Applied to Perforated Sheet Metals

  • Research Article-Mechanical Engineering
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Abstract

Single point incremental forming (SPIF) of sheet metal is a process that is widely used for rapid prototyping and small series production. The process is known for its flexibility, performance, and ease of use in forming custom parts with complex geometries. However, SPIF seems to present many challenges, especially its use in the biomedical sector, where control of operating parameters and compliance with component dimensions are production qualification requirements. This includes springback, which particularly affects the dimensional and geometric compliance of the formed part to the programmed one. This paper describes the results obtained from a design of experiment (DOE) related to the forming process of perforated plates produced by the SPIF process applied to AZ31B Magnesium alloy. The comparative analysis between the responses of obtained parts without holes and obtained ones from perforated plates showed discrepancies between the collected responses.

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Abbreviations

SPIF:

Single point incremental sheet forming

DOE:

Design of experiment

AZ31B:

Magnesium alloy

\({\mu }_{i}\) :

Friction indicator

\({F}_{z}\) :

Axial forming force for perforated sheet

\({F}_{f}\) :

Passive resistance to the feed of the forming tool

\({F}_{\mathrm{form}}\) :

Force resisting the sheet deformation of

\({F}_{X}, {F}_{Y}\) :

Forming force in (X, Y) plane

\({T}_{zt}\) :

Total measured torque

\({T}_{zc}\) :

Cinematic measured torque

\({S}_{sc}\) :

Step screw CNC machine

\({F}_{Z0}\) :

Unperforated sheet vertical force

\({F}_{Zt}\) :

Total vertical force

\({F}_{ZC}\) :

Cinematic vertical force

\({F}_{Z \mathrm{sensor}}\) :

Vertical sensor force

\({F}_{Z \mathrm{CNC}}\) :

Vertical CNC machine force

\({F}_{Za}\) :

Adjusted vertical force

\(\lambda \) :

Adjusted coefficient force

\({F}_{z\mathrm{exp}}\) :

Experimental vertical forming force

\({F}_{z\mathrm{pred}}\) :

Predictive vertical forming force

\({K}_{\mathrm{Sp}}, K\) :

Perforated sheet springback

\({K}_{\mathrm{Sp}0}, {K}_{0}\) :

Unperforated sheet springback

\({K}_{\mathrm{C}}\) :

Programed path offset

\(\mathrm{NI}\) :

National Instrument

\({G}_{\mathrm{Fz}}\left(\%\right)\) :

Relative gap between perforated and unperforated forces

\({G}_{\mathrm{sp}}(\%)\) :

Relative gap between perforated and unperforated springback

\({K}_{\mathrm{W}}\) :

Wall angle offset

\({K}_{\mathrm{exp}}\) :

Experimental springback

\({K}_{\mathrm{pred}}\) :

Predictive springback

\({Z}_{\mathrm{CAD}}\) :

Vertical depth of CAD model

\({Z}_{0}\) :

Vertical depth of unperforated sheet

\(Z\) :

Vertical depth of perforated sheet

\({D}_{T}\) :

Tool diameter

\(\Delta Z\) :

Vertical step down

\(S\) :

Spindle speed

\({D}_{\mathrm{h}}\) :

Hole diameter

\({H}_{\mathrm{g}}\) :

Hole grid

\(\mathrm{DOF}\) :

Degree of freedom

\(F\text{-value}\) :

Fisher test value

\(P\,\mathrm{ value}\) :

Value of significance

\(C\boldsymbol{\%}\) :

Percentage of contribution

\(\mathrm{SS}\) :

Sum of Squared deviations

\(\mathrm{MS}\) :

Mean squares

\({R}^{2}\) :

Determination coefficient

\({R}_{\mathrm{ad}}^{2}\) :

Adjusted determination coefficient

\({\delta }_{\mathrm{F}}\left(\boldsymbol{\%}\right)\) :

Relative gap between predicted and experimental forces

\({\delta }_{\mathrm{K}}\left(\boldsymbol{\%}\right)\) :

Relative gap between predicted and experimental springback

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Authors and Affiliations

  1. National Engineering School of Tunis, University of Tunis El Manar, le Belvédère, BP 37, 1200, Tunis, Tunisia

    Slim Bouzidi

  2. National Engineering School of Bizerte, University of Carthage, Campus Universitaire Menzel Abderrahman, BP 66, 7035, Bizerte, Tunisia

    Mahfoudh Ayadi

  3. National Institute of Applied Sciences and Technology, University of Carthage, Centre Urbain Nord, BP 676, 1080, Tunis, Tunisia

    Atef Boulila

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Bouzidi, S., Ayadi, M. & Boulila, A. Feasibility Study of the SPIF Process Applied to Perforated Sheet Metals. Arab J Sci Eng 47, 9225–9252 (2022). https://doi.org/10.1007/s13369-022-06570-6

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