• 한국생산제조학회지
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• 제22권5호
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• pp.800-805
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• 2013

Incremental forming of sheet metal is a modern method of forming sheet metal, where parts can be formed without the use of dedicated dies. Existing experimental configurations for incremental forming can be broadly classified into two categories, i.e., negative and positive forming. In this paper, forming qualities such as shape accuracy and surface roughness of Al 1050 material were discussed for different forming methods. The formed and the corresponding opposing surfaces were measured with a three-dimensional scanner and a surface roughness tester. It was found that in terms of shape accuracy, the best opposing surface was obtained with positive forming, whereas the worst formed surface was obtained with negative forming; furthermore, the opposing surface is always better than the formed surface, regardless of the forming method used.

• 산업경영시스템학회지
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• 제38권4호
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• pp.177-183
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• 2015

Incremental sheet metal forming is a manufacturing process to produce thin parts using sheet metals by a series of small incremental deformation. The process rarely needs dedicated dies and molds, thus, preparation time for the process is relatively short as to be compared to conventional metal forming. Spring back in sheet metal working is very common, which causes critical errors in dimensions. Incremental sheet metal forming is not fully investigated yet. Hence, incremental sheet metal forming frequently produces inaccurate parts. This paper proposes a method to minimize dimensional errors to improve shape accuracy of products manufactured by incremental forming. This study conducts experiments using an exclusive incremental forming machine and the material for these experiments are sheets of aluminum AL1015. This research defines a process parameter and selects a few factors for the experiments. The parameters employed in this paper are tool feed rate, tool diameter, step depth, material thickness, forming method, dies applied, and tool path method. In addition, their levels for each factor are determined. The plan of the experiments is designed using orthogonal array $L_8$ ($2^7$) which requires minimum number of experiments. Based on the measurements, dimensional errors are collected both on the tool contacted surfaces and on the non-contacted surfaces. The distances between the formed surfaces and the CAD models are scanned and recorded using a commercial software product. These collected data are statistically analyzed and ANOVAs (analysis of variances) are drawn up. From the ANOVAs, this paper concludes that the process parameters of tool diameter, forming depth, and forming method are the significant factors to reduce the errors on the tool contacted surface. On the other hand, the experimental factors of forming method and dies applied are the significant factors on the non-contacted surface. However, the negative forming method always produces better accuracy than the positive forming method.

• 한국생산제조학회지
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• 제23권5호
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• pp.512-518
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• 2014

In this paper, the influence of part shape complexity and die type on forming accuracy in incremental sheet metal forming is presented. The part shape complexities are classified into two types, namely, of one and two-step shapes. Correspondingly, die types are classified into three types, namely, of no-, partial, and full die types. The experimental tests are performed separately on negative and positive forming methods. It is shown that for the one-step shape, there are no significant differences in forming errors between the cases of no- and full die types when the negative forming method is used. Furthermore, the full die type is better than the partial die when positive forming is used. For the two-step shape case, the full die type always exhibits better forming accuracy than the no- and partial die types, irrespective of the forming method used.

• 한국기계가공학회지
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• 제13권6호
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• pp.66-72
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• 2014

Incremental forming is a relatively novel sheet forming process, in which parts can be formed without the use of dedicated dies. In this paper, the influence of the process parameters (tool diameter, step size, feed rate, existence of a die, forming methods, and kinds of tool path) on surface roughness in the case in which parts are processed by incremental forming was discussed. Al 1050 material is used in the experiments. A table of orthogonal arrays is used to design the experiments and the ANOVA method is employed to statistically analyze the results. The obtained results show that the process parameters of tool diameter, step size, and the existence of a die have a significant effect on the surface roughness, whereas the feed rate, forming methods and kinds of tool path are insignificant.