Optimal process planning for energy consumption and product quality during double-sided incremental forming

Reddy, N Venkata (2023) Optimal process planning for energy consumption and product quality during double-sided incremental forming. International Journal of Advanced Manufacturing Technology, 125 (7-8). pp. 3305-3327. ISSN 0268-3768

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Double-sided incremental forming (DSIF) process is gaining industrial importance as it has the capability to form complex 3D sheet metal components without using component-specific tooling. It is necessary to form the components in an energy-efficient way without compromising on quality. Almost all the earlier attempts on the energy analysis of single point incremental forming (which is less preferable as it results in poor accuracy, formed components of opening size less than 200 mm × 200 mm) focused on the energy consumption (predicted using either measured forming forces or power) under various process parameters and different machine tools. Energy necessary for free traverse of tools in predefined path is much higher compared to that required to plastically deform the sheet. Energy/power required for free traverse of tool is the significant contributor to the total energy when the tools have to move against the gravity (as in the case of scaled-up machines). Therefore, strategies to reduce energy consumption to move the tools need to be developed, and the present work is an attempt towards the same. In the present work, a mechanics-based model is developed to predict power and energy consumption (i.e., during free movement of tools and to deform sheet) during forming of any arbitrary geometry considering the chosen DSIF machine configuration. Predicted variation in power with forming time for various geometries is compared with measured ones, and they are in excellent agreement. Analysis is carried out to select the process parameters such that energy required to plastically deform the sheet is reasonably less with good surface quality. The effect of component orientation on energy consumption is emphasized. Finally, a process planning strategy is proposed (that includes selecting process parameters and using them to estimate deflection compensations for enhancing accuracy, choosing component orientation, tool type, support force) to form the components with improved surface quality and accuracy in an energy-efficient way. Results indicate that the energy consumption is reduced in the range of 10 to 50% for the geometries formed at an optimal orientation using the self-rotating tools.

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IITH Creators:
IITH CreatorsORCiD
Reddy, N Venkatahttp://www.orcid.org/0000-0002-0894-9734
Item Type: Article
Uncontrolled Keywords: Component orientation; Deflection compensations; Double-sided incremental forming; Prediction of energy consumption; Surface roughness; Tool design; Energy efficiency; Geometry; Machine tools; Product design; Quality control; Sheet metal; Surface properties; Surface roughness; Component orientation; Deflection compensations; Double sided; Double-sided incremental forming; Energy efficient; Energy-consumption; Incremental forming; Prediction of energy consumption; Process parameters; Tool designs; Energy utilization
Subjects: Physics > Mechanical and aerospace
Physics > Mechanical and aerospace > Transportation Science & Technology
Divisions: Department of Mechanical & Aerospace Engineering
Depositing User: Mr Nigam Prasad Bisoyi
Date Deposited: 15 Sep 2023 07:01
Last Modified: 15 Sep 2023 07:01
URI: http://raiith.iith.ac.in/id/eprint/11685
Publisher URL: https://doi.org/10.1007/s00170-023-10948-7
OA policy: https://v2.sherpa.ac.uk/id/publication/13456
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