Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study
Incremental sheet forming (ISF) requires no or partial dies for sheet metal fabrication and is widely used for small batch production. In this process, necking is either suppressed or delayed due to the localized nature of tool–sheet contact; hence, more strains than conventional stamping and deep d...
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MDPI AG
2023-03-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/13/3/568 |
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| author | Ravi Prakash Singh Santosh Kumar Sarang Pande Sachin Salunkhe Adham E. Ragab Pankaj Kumar Singh Md Meraz J. Paulo Davim |
| author_facet | Ravi Prakash Singh Santosh Kumar Sarang Pande Sachin Salunkhe Adham E. Ragab Pankaj Kumar Singh Md Meraz J. Paulo Davim |
| author_sort | Ravi Prakash Singh |
| collection | DOAJ |
| description | Incremental sheet forming (ISF) requires no or partial dies for sheet metal fabrication and is widely used for small batch production. In this process, necking is either suppressed or delayed due to the localized nature of tool–sheet contact; hence, more strains than conventional stamping and deep drawing are obtained. In the present study, two variations of ISF, namely cold ISF (CISF) and warm ISF (WISF), are compared. First, FEA modeling is carried out on ABAQUS to reach the forming forces involved in the process. It is found that WISF reduces the forming forces. The temperature for WISF is maintained at 180 °C. Following the simulation analysis, tests are carried out. The forming force in WISF is 55.77% less than that in CISF. The part fabricated by CISF is slightly more substantial than that by WISF; however, more forming depth can be achieved by WISF. There is a more uniform thickness distribution in the case of CISF than in WISF. However, the surface quality of the CISF product is inferior to that of WISF. It is observed that there is reduced forming force, increased formability, and better strain distribution in WISF compared to CISF. However, post-processing heat treatment and surface polishing of the formed parts is required to restore their mechanical properties. |
| first_indexed | 2024-03-11T06:10:10Z |
| format | Article |
| id | doaj.art-5ab6758afbac449b9969dff5d62cbd12 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-11T06:10:10Z |
| publishDate | 2023-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-5ab6758afbac449b9969dff5d62cbd122023-11-17T12:39:34ZengMDPI AGMetals2075-47012023-03-0113356810.3390/met13030568Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative StudyRavi Prakash Singh0Santosh Kumar1Sarang Pande2Sachin Salunkhe3Adham E. Ragab4Pankaj Kumar Singh5Md Meraz6J. Paulo Davim7Department of Mechanical Engineering, IIT (BHU), Varanasi 221005, IndiaDepartment of Mechanical Engineering, IIT (BHU), Varanasi 221005, IndiaDepartment of Mechanical Engineering, Marwadi University, Rajkot 360003, IndiaDepartment of Mechanical Engineering, Vel-Tech Rangarajan Dr Sagunthala R&D Institute of Science and Technology, Avadi, Chennai 600062, IndiaDepartment of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi ArabiaDepartment of Mechanical Engineering, IIT (BHU), Varanasi 221005, IndiaDepartment of Mechanical Engineering, IIT (BHU), Varanasi 221005, IndiaDepartment of Mechanical Engineering, Campus Santiago, University of Aveiro, 3810-193 Aveiro, PortugalIncremental sheet forming (ISF) requires no or partial dies for sheet metal fabrication and is widely used for small batch production. In this process, necking is either suppressed or delayed due to the localized nature of tool–sheet contact; hence, more strains than conventional stamping and deep drawing are obtained. In the present study, two variations of ISF, namely cold ISF (CISF) and warm ISF (WISF), are compared. First, FEA modeling is carried out on ABAQUS to reach the forming forces involved in the process. It is found that WISF reduces the forming forces. The temperature for WISF is maintained at 180 °C. Following the simulation analysis, tests are carried out. The forming force in WISF is 55.77% less than that in CISF. The part fabricated by CISF is slightly more substantial than that by WISF; however, more forming depth can be achieved by WISF. There is a more uniform thickness distribution in the case of CISF than in WISF. However, the surface quality of the CISF product is inferior to that of WISF. It is observed that there is reduced forming force, increased formability, and better strain distribution in WISF compared to CISF. However, post-processing heat treatment and surface polishing of the formed parts is required to restore their mechanical properties.https://www.mdpi.com/2075-4701/13/3/568incremental formingwarm formingstraight groove testErichsen cup test |
| spellingShingle | Ravi Prakash Singh Santosh Kumar Sarang Pande Sachin Salunkhe Adham E. Ragab Pankaj Kumar Singh Md Meraz J. Paulo Davim Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study Metals incremental forming warm forming straight groove test Erichsen cup test |
| title | Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study |
| title_full | Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study |
| title_fullStr | Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study |
| title_full_unstemmed | Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study |
| title_short | Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study |
| title_sort | robot assisted cold and warm incremental sheet forming of aluminum alloy 6061 a comparative study |
| topic | incremental forming warm forming straight groove test Erichsen cup test |
| url | https://www.mdpi.com/2075-4701/13/3/568 |
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