Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming
This project investigates the influence of various processing parameters on the formability of hole flanging process using Incremental Sheet Forming (ISF) method. Parameters selected were tool diameter, tool shape, step size, feed rate, and toolpath strategy. Data collected included force data...
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| Other Authors: | |
| Format: | Final Year Project (FYP) |
| Language: | English |
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Nanyang Technological University
2024
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| Online Access: | https://hdl.handle.net/10356/181654 |
| _version_ | 1826129857419935744 |
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| author | Kiera, Kathleen |
| author2 | Paulo Jorge Da Silva Bartolo |
| author_facet | Paulo Jorge Da Silva Bartolo Kiera, Kathleen |
| author_sort | Kiera, Kathleen |
| collection | NTU |
| description | This project investigates the influence of various processing parameters on the formability of
hole flanging process using Incremental Sheet Forming (ISF) method. Parameters selected
were tool diameter, tool shape, step size, feed rate, and toolpath strategy. Data collected
included force data from the ISF robot, 3D scanning of the completed workpiece, and
simulation work to supplement the findings. Results were analysed under 3 broad categories
of fractural, geometrical, and surficial areas. Formability was optimised for tool diameter at a
middle value of around 10-15mm. Experiments for tool shape showed hemispherical being
beneficial over flat tool for all 3 areas. Increase in step size showed improvement in the
fractural area however worsened surficial considerations. Increase in feed rate resulted in
accelerated onset of fracture. Multi-stage toolpath strategy showed improvements across all 3
categories. Plot of force data generated by the robot against depth presented key features
corresponding to the time position of the forming process. Force monitoring as a reflection of
fracture occurrence was only possible under certain fracture conditions. Simulation work
enhanced understanding of the stress-strain conditions experienced by the workpiece due to
the forming process under certain selected sets of parameters. Future possible work includes
varying blank size diameters in smaller increments, use of more simulation work and assisted
ISF such as using heat or vibration. |
| first_indexed | 2025-03-09T15:12:23Z |
| format | Final Year Project (FYP) |
| id | ntu-10356/181654 |
| institution | Nanyang Technological University |
| language | English |
| last_indexed | 2025-03-09T15:12:23Z |
| publishDate | 2024 |
| publisher | Nanyang Technological University |
| record_format | dspace |
| spelling | ntu-10356/1816542024-12-14T16:52:50Z Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming Kiera, Kathleen Paulo Jorge Da Silva Bartolo School of Mechanical and Aerospace Engineering Singapore Institute of Manufacturing Technology pbartolo@ntu.edu.sg Engineering Incremental sheet forming Hole flanging This project investigates the influence of various processing parameters on the formability of hole flanging process using Incremental Sheet Forming (ISF) method. Parameters selected were tool diameter, tool shape, step size, feed rate, and toolpath strategy. Data collected included force data from the ISF robot, 3D scanning of the completed workpiece, and simulation work to supplement the findings. Results were analysed under 3 broad categories of fractural, geometrical, and surficial areas. Formability was optimised for tool diameter at a middle value of around 10-15mm. Experiments for tool shape showed hemispherical being beneficial over flat tool for all 3 areas. Increase in step size showed improvement in the fractural area however worsened surficial considerations. Increase in feed rate resulted in accelerated onset of fracture. Multi-stage toolpath strategy showed improvements across all 3 categories. Plot of force data generated by the robot against depth presented key features corresponding to the time position of the forming process. Force monitoring as a reflection of fracture occurrence was only possible under certain fracture conditions. Simulation work enhanced understanding of the stress-strain conditions experienced by the workpiece due to the forming process under certain selected sets of parameters. Future possible work includes varying blank size diameters in smaller increments, use of more simulation work and assisted ISF such as using heat or vibration. Bachelor's degree 2024-12-11T23:41:25Z 2024-12-11T23:41:25Z 2024 Final Year Project (FYP) Kiera, K. (2024). Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming. Final Year Project (FYP), Nanyang Technological University, Singapore. https://hdl.handle.net/10356/181654 https://hdl.handle.net/10356/181654 en application/pdf Nanyang Technological University |
| spellingShingle | Engineering Incremental sheet forming Hole flanging Kiera, Kathleen Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| title | Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| title_full | Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| title_fullStr | Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| title_full_unstemmed | Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| title_short | Optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| title_sort | optimising process parameters and toolpath strategies for sheet metal flanging in incremental sheet forming |
| topic | Engineering Incremental sheet forming Hole flanging |
| url | https://hdl.handle.net/10356/181654 |
| work_keys_str_mv | AT kierakathleen optimisingprocessparametersandtoolpathstrategiesforsheetmetalflanginginincrementalsheetforming |