Yan Zhou, Hassanin Hany, El-Sayed Mahmoud Ahmed, Eldessouky Hossam Mohamed, Djuansjah Jrp, A Alsaleh Naser, Essa Khamis, Ahmadein Mahmoud
School of Engineering, University of Birmingham, Birmingham B152TT, UK.
School of Engineering, Technology, and Design, Canterbury Christ Church University, Canterbury CT1 1QU, UK.
Materials (Basel). 2021 Nov 11;14(22):6794. doi: 10.3390/ma14226794.
Single-point incremental forming (SPIF) is a flexible technology that can form a wide range of sheet metal products without the need for using punch and die sets. As a relatively cheap and die-less process, this technology is preferable for small and medium customised production. However, the SPIF technology has drawbacks, such as the geometrical inaccuracy and the thickness uniformity of the shaped part. This research aims to optimise the formed part geometric accuracy and reduce the processing time of a two-stage forming strategy of SPIF. Finite element analysis (FEA) was initially used and validated using experimental literature data. Furthermore, the design of experiments (DoE) statistical approach was used to optimise the proposed two-stage SPIF technique. The mass scaling technique was applied during the finite element analysis to minimise the computational time. The results showed that the step size during forming stage two significantly affected the geometrical accuracy of the part, whereas the forming depth during stage one was insignificant to the part quality. It was also revealed that the geometrical improvement had taken place along the base and the wall regions. However, the areas near the clamp system showed minor improvements. The optimised two-stage strategy successfully decreased both the geometrical inaccuracy and processing time. After optimisation, the average values of the geometrical deviation and forming time were reduced by 25% and 55.56%, respectively.
单点渐进成形（SPIF）是一种灵活的技术，无需使用冲模即可成形各种钣金产品。作为一种相对廉价的无模工艺，该技术适用于中小型定制生产。然而，SPIF技术也存在缺点，如成形零件的几何精度和厚度均匀性问题。本研究旨在优化成形零件的几何精度，并减少SPIF两阶段成形策略的加工时间。首先使用有限元分析（FEA）并通过实验文献数据进行验证。此外，采用实验设计（DoE）统计方法对提出的两阶段SPIF技术进行优化。在有限元分析过程中应用了质量缩放技术，以最小化计算时间。结果表明，第二成形阶段的步长对零件的几何精度有显著影响，而第一阶段的成形深度对零件质量影响不大。还发现沿底部和壁部区域的几何形状有改善。然而，夹具系统附近的区域改善较小。优化后的两阶段策略成功降低了几何误差和加工时间。优化后，几何偏差和成形时间的平均值分别降低了25%和55.56%。
