A new flexible multi-point incremental sheet forming process with multi-layer sheets

Zhao, Xuelei; Ou, Hengan

Abstract

In this research, a new flexible multi-point incremental sheet forming process with multi-layer sheets (F-MPIF-MLS) was proposed. The novelty of this new forming process is demonstrated by two specific aspects of contribution. The first is the development of a new flexible multi-point die system to replace the conventional multi-point die, in which the multi-point pins are in contact with and provide support to the blank sheet from the start to the end of the forming operation. The second is the use of multi-layer sheets, which allows the target blank sheet to be deformed without clamping constraints. The new F-MPIF-MLS process clearly shows the benefits of overcoming the limitations of excessive sheet thinning and poor surface finish of the existing conventional multi-point incremental sheet forming (MPIF) process. A detailed comparative investigation into the new F-MPIF-MLS and the conventional MPIF processes is conducted through experimental testing and finite element (FE) simulation. The results show a noticeable reduction of wrinkling by using the new flexible multi-point die over the conventional multi-point die system with multi-layer sheets to form a dome shape. Moreover, in using the new F-MPIF-MLS process, the maximum thickness reduction is significantly reduced from 35% to 5% as compared to the conventional MPIF process to achieve a more uniform thickness distribution of the formed part.

Citation

Zhao, X., & Ou, H. (2023). A new flexible multi-point incremental sheet forming process with multi-layer sheets. Journal of Materials Processing Technology, 322, Article 118214. https://doi.org/10.1016/j.jmatprotec.2023.118214

• Journal Article Type: Article
• Acceptance Date: Nov 11, 2023
• Online Publication Date: Nov 16, 2023
• Publication Date: 2023-12
• Deposit Date: Nov 21, 2023
• Publicly Available Date: Nov 22, 2023
• Journal: Journal of Materials Processing Technology
• Print ISSN: 0924-0136
• Electronic ISSN: 1873-4774
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 322
• Article Number: 118214
• DOI: https://doi.org/10.1016/j.jmatprotec.2023.118214
• Keywords: Incremental sheet forming; Flexible multi-point sheet forming; Sheet thinning; Wrinkling; Formability
• Public URL: https://nottingham-repository.worktribe.com/output/27590355
• Publisher URL: https://www.sciencedirect.com/science/article/pii/S092401362300359X?via%3Dihub