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Journal articles on the topic 'Tool forming'

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Author: Grafiati

Published: 30 May 2022

Last updated: 31 May 2022

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1

Cser, L., M. Geiger, K. Lange, J. A. G. Kals, and M. Hänsel. "Tool Life and Tool Quality in Bulk Metal Forming." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 207, no. 4 (November 1993): 223–39. http://dx.doi.org/10.1243/pime_proc_1993_207_085_02.

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Due to their intermediate position between the machine and workpiece, tools represent the interface of the manufacturing system to the process. Near net shape production, new materials and techniques are the new challenges in metal forming and especially in tooling. A significant economical effect can be achieved through an increase in the life of tool elements, as well as through proper tool management strategies. The greatest problem connected with the preliminary estimation of tool life is the large scatter of service life for a series of identically designed tools. The uncertainty in estimating the expected service life of tools and thus the tooling costs per piece is caused by the enormous variety and confluence of damaging factors, the factory-specific character of tool life and the stochastic phenomenon of tool failures. From the confluence of aspects influencing tool life it is clear that there is no general recipe for increasing tool life and tool quality. Each of the influencing aspects contains some possibilities for increasing the service time of tools. This paper shows some examples of tool design and tool manufacturing and points out that a knowledge-based approach imitating the activity and knowledge acquisition of human experts can be the bridge between computer aided (CA) techniques and human experience in predicting expected tool life.

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2

Meier, Horst, V. Smukala, O. Dewald, and Jian Zhang. "Two Point Incremental Forming with Two Moving Forming Tools." Key Engineering Materials 344 (July 2007): 599–605. http://dx.doi.org/10.4028/www.scientific.net/kem.344.599.

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This paper describes a new development of an incremental, robot based sheet metal forming process for the production of sheet metal components for limited-lot productions and prototypes. The kinematic based generation of the shape is implemented by means of two industrial robots, which are interconnected to a cooperating robot system. Compared to other incremental sheet metal forming machines this system offers a high geometrical form flexibility without the need of any workpiece dependent tools. The principle of the procedure is based on flexible shaping by means of a freely programmable path-synchronous movement of two robots. So far, the final shape is produced by the incremental infeed of the forming tool in depth direction and its movement along the contour in lateral direction on each level. The counter tool, with its simple geometry, was used to support the sheet metal on the backside by moving synchronously along the outer contour, constantly on the same level. This corresponds to a fixed backplate used in other incremental sheet metal forming processes. Due to the use of a new robot system with extended control algorithms for cooperating robots, it will be possible to release the counter tool from its constant path on the outer contour and support the forming tool right on the opposite side of the sheet to generate a predefined gap between the two hemispherical tools. This way at each moment a small part of a full die, as it is used in other processes, is simulated without the need of producing a workpiece dependent die. The extended payload of the new robot system gives the opportunity to form steel blanks, for the first time.

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3

Mizelle, John Christopher, Teresa Tang, Nikta Pirouz, and Lewis A. Wheaton. "Forming Tool Use Representations: A Neurophysiological Investigation into Tool Exposure." Journal of Cognitive Neuroscience 23, no. 10 (October 2011): 2920–34. http://dx.doi.org/10.1162/jocn_a_00004.

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Prior work has identified a common left parietofrontal network for storage of tool-related information for various tasks. How these representations become established within this network on the basis of different modes of exposure is unclear. Here, healthy subjects engaged in physical practice (direct exposure) with familiar and unfamiliar tools. A separate group of subjects engaged in video-based observation (indirect exposure) of the same tools to understand how these learning strategies create representations. To assess neural mechanisms engaged for pantomime after different modes of exposure, a pantomime task was performed for both tools while recording neural activation with high-density EEG. Motor planning–related neural activation was evaluated using beta band (13–22 Hz) event-related desynchronization. Hemispheric dominance was assessed, and activation maps were generated to understand topography of activations. Comparison of conditions (effects of tool familiarity and tool exposure) was performed with standardized low-resolution brain electromagnetic tomography. Novel tool pantomime following direct exposure resulted in greater activations of bilateral parietofrontal regions. Activations following indirect training varied by tool familiarity; pantomime of the familiar tool showed greater activations in left parietofrontal areas, whereas the novel tool showed greater activations at right temporoparieto-occipital areas. These findings have relevance to the mechanisms for understanding motor-related behaviors involved in new tools that we have little or no experience with and can extend into advancing theories of tool use motor learning.

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4

Sieczkarek, Peter, Lukas Kwiatkowski, A. Erman Tekkaya, Eugen Krebs, Petra Kersting, W. Tillmann, and Jan Herper. "Innovative Tools to Improve Incremental Bulk Forming Processes." Key Engineering Materials 554-557 (June 2013): 1490–97. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1490.

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Sheet-bulk metal forming is an innovative process with a high potential to generate load-adapted parts with high precision. Bulk forming processes of sheet metals especially require high process forces, resulting in an intense contact pressure and, thus, in a very high abrasive and adhesive wear. As a method to reduce or avoid these common wear phenomena, even hardened or coated tool surfaces are not sufficient. The objective of this paper is to show an improvement of the tool resistance during an incremental forming process by an adapted tool design and the application of structured tool surfaces combined with coatings. For the tool surface the structure of the scarabaeus beetle serves as the basis for a bionic structure. This structure was manufactured by micromilling. Despite the high hardness of the tool material and the complex geometry of the forming tools, very precise patterns were machined successfully using ball-end milling cutters. The combination of bionic structures with coating techniques like physical vapor deposition (PVD) on plasma nitrided tool surfaces is very promising. In this work, the influence of process parameters (workpiece material, lubrication, tool design, stepwise infeed) on the tool resistance during the forming operation was analyzed experimentally. The results of the optimized forming tools were compared to conventional, unstructured, uncoated, and only plasma nitrided forming tools. The different tools were applied to 2 mm thick metal sheets made of aluminum (AlMg3) and steel (non-alloy quality steel DC04). As a result, the process forces could be reduced by a modified shape and surface of the tools. Thus, the lifetime of the tools can be enhanced.

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5

Lange, K., L. Cser, M. Geiger, and J. A. G. Kals. "Tool Life and Tool Quality in Bulk Metal Forming." CIRP Annals 41, no. 2 (1992): 667–75. http://dx.doi.org/10.1016/s0007-8506(07)63253-3.

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6

Lämsä, Janne, Antti Järvenpää, and Kari Mäntyjärvi. "Designing and Manufacturing of a Flexible Longitudinally Laminated Sandwich Panel Forming Tool." Key Engineering Materials 611-612 (May 2014): 786–93. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.786.

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The main aim of the study was to develop forming tools for wide (over 1.2 meter) sandwich panels. Longitudinal laminating technology was selected for tool manufacturing due to its flexibility and cost efficiency. Laminating technology enables easy modification of the tool dimensions afterwards. The function to optimize or vary the dimensions of the tool was set as a secondary objective for the study. Forming tools for sandwich panels are usually complicated structures and joining of the plates can be difficult in some cases. Typically sandwich forming tools are capable to produce only narrow panels (less than 1 meter) and optimization must be done during designing of the tool. In this study, a rapid designing and manufacturing of a flexible sandwich panel forming tool was investigated. Sandwich panels are usually applied in light structures or voice covers due to their very low weight, high stiffness, durability and production cost savings. Designing of the forming tool was made by using a 3D CAD program. Conventional steel plates were used for the forming tool and the assembly was done by fixing the plate parts longitudinally together (laminating). Most important criterion for the forming tool was its capability to produce high quality geometry for the core. Laser welding assembly showed that the quality of the core was good enough for welding the lap joints properly. Both of the objectives were fulfilled: 1) forming tools were suitable for forming of wide cores (1.2 meter) and 2) the structure of the laminated tool enables to change or add new plate parts to change the dimensions of the final product.

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7

Herrmann, Marius, Florian Böhmermann, Henning Hasselbruch, Bernd Kuhfuss, Oltmann Riemer, Andreas Mehner, and Hans-Werner Zoch. "Forming without Lubricant – Functionalized Tool Surfaces for Dry Forming Applications." Procedia Manufacturing 8 (2017): 533–40. http://dx.doi.org/10.1016/j.promfg.2017.02.068.

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8

Allaoui, S., J. Launay, D. Soulat, and S. Chatel. "Experimental tool of woven reinforcement forming." International Journal of Material Forming 1, S1 (April 2008): 815–18. http://dx.doi.org/10.1007/s12289-008-0260-4.

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9

Lamprecht, M., and M. Leonhartsberger. "Tool Stiffness Calculation in Roll Forming." International Journal of Simulation Modelling 20, no. 1 (March 10, 2021): 40–51. http://dx.doi.org/10.2507/ijsimm20-1-539.

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10

Qin, Yi. "Forming-tool design innovation and intelligent tool-structure/system concepts." International Journal of Machine Tools and Manufacture 46, no. 11 (September 2006): 1253–60. http://dx.doi.org/10.1016/j.ijmachtools.2006.01.013.

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11

Bedan, Aqeel Sabree, and Halah Ali Habeeb. "Experimental Study the Effect of Tool Geometry on Dimensional Accuracy in Single Point Incremental Forming (SPIF) Process." Al-Nahrain Journal for Engineering Sciences 21, no. 1 (February 10, 2018): 108. http://dx.doi.org/10.29194/njes21010108.

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Incremental forming is a flexible sheet metal forming process which performed by utilizes simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. One limitations of single point incremental forming (SPIF) process is the error occur between the CAD design and the product profile. This work presents the single point incremental forming process for produced pyramid geometry and studied the effect of tool geometry, tool diameter, wall angle, and spindle speed on the dimensional accuracy. Three geometries of forming tools were used in experimental work: ball end tool, hemispherical tool, and flat with round corner tool. The sheet material used was pure Aluminum (Al 1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The products dimensions were measured by utilized the dimensional sensor measuring instrument. The extracted results from the single point incremental forming process indicated the best acceptance between the CAD profile and product profile was found with the ball end tool and diameter of (10 mm), wall angle (50°) and the rotational speed of the tool was (800 rpm).

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12

Jiang, Wei, Takuya Miura, Masato Okada, Ryo Matsumoto, and Masaaki Otsu. "Improvement of Forming Limit in Height with Alternating Tool Path in Penetrating Tool Friction Stir Incremental Forming." MATERIALS TRANSACTIONS 61, no. 5 (May 1, 2020): 1000–1007. http://dx.doi.org/10.2320/matertrans.p-m2020807.

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13

Ham, M., B. M. Powers, and J. Loiselle. "Surface Topography from Single Point Incremental Forming Using an Acetal Tool." Key Engineering Materials 549 (April 2013): 84–91. http://dx.doi.org/10.4028/www.scientific.net/kem.549.84.

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This paper investigates a new tool, where the forming tip is constructed from acetal. The acetal tip is investigated because it is self-lubricating and more compliant than traditional SPIF tools. This work characterizes the topography of surfaces created by forming aluminum with both the acetal-tipped tool and a carbide tool. When the parts are compared visually, the parts formed with the acetal tool maintain the appearance of the unformed sheet metal. The surfaces of the parts are measured using an Olympus LEXT OLS4000, a vertical scanning laser confocal microscope. Surface height as a function of lateral position on both sides of the parts (contact and free surface) is measured. These measurements are analyzed quantitatively using areal surface texture parameters and qualitatively compared with micrographs of the surfaces. Comparisons of the surfaces that are in contact with the tool reveal that the surfaces produced with the acetal tool are rougher but more isotropic than those produced using the carbide tool. The surfaces produced by the carbide tool have a more anisotropic appearance, which is created by the tool as it steps down to form the part. The benefit of using the acetal tool rather than the carbide tool is the absence of the anisotropy caused by tool step down. The free surfaces produced by both tools are much rougher than the surfaces that contact the forming tools, since the tool does not affect roughness of the free surfaces.

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14

Wang, Yan Tao. "Design of Rolling Tool System for Fin Forming Machine." Applied Mechanics and Materials 44-47 (December 2010): 512–16. http://dx.doi.org/10.4028/www.scientific.net/amm.44-47.512.

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The method to develop the rolling tool system for the fin forming machine is presented in this paper. The principle of the waveform shaping is analyzed and different schemes of the rolling tool are built and discussed. After the selected of the most optimization of the rolling tool scheme, the parameter design of the rolling tool is calculated. Correspondingly, the other auxiliary components of the fin forming machine are proposed. In the end, the whole assembly of the rolling toll system is discussed. The development of the fin forming machine used this rolling tool system will achieve a variety of specification fin products.

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15

Wu, S. H., Ana Reis, F. M. Andrade Pires, Abel D. Santos, and A. Barata da Rocha. "Study of Tool Trajectory in Incremental Forming." Advanced Materials Research 472-475 (February 2012): 1586–91. http://dx.doi.org/10.4028/www.scientific.net/amr.472-475.1586.

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Single point incremental forming (SPIF) is an innovative flexible sheet metal forming process which can be used to produce complex shapes from various materials. Due to its flexibility, it attracts a more and more attention in the recent decades. Several studies show that besides the major operating parameters, namely feed rate, tool radius, and forming speed etc., tool path is also an important processing parameter to affect the final forming component. In view of that, the present paper studies the influence of tool paths on the work piece quality by the finite element method coupled with the Continuum Damage Mechanics (CDM) model. The formability of incremental forming in different tool paths is also analyzed.

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16

HAYASHI, Kazuo, and Kenji FUCHIWAKI. "Net Shape Forming Tool Technology of Fineblanking." Journal of the Japan Society for Technology of Plasticity 51, no. 592 (2010): 400–404. http://dx.doi.org/10.9773/sosei.51.400.

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17

MORAVEC, J�n. "Unconventional cavity forming using a machine tool." HUTNIK - WIADOMOŚCI HUTNICZE 1, no. 9 (August 10, 2016): 39–43. http://dx.doi.org/10.15199/24.2016.9.11.

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18

Mojžíšek, Martin. "Triplex Forming Oligonucleotides – Tool for Gene Targeting." Acta Medica (Hradec Kralove, Czech Republic) 47, no. 3 (2004): 151–56. http://dx.doi.org/10.14712/18059694.2018.82.

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This review deals with the antigene strategy whereby an oligonucleotide binds to the major or minor groove of double helical DNA where it forms a local triple helix. Preoccupation of this article is triplex-forming oligonucleotides (TFO). These are short, synthetic single-stranded DNAs that recognize polypurine:polypyrimidine regions in double stranded DNA in a sequence-specific manner and form triplex. Therefore, the mechanisms for DNA recognition by triple helix formation are discussed, together with main characteristics of TFO and also major obstacles that remain to be overcome are highlighted. TFOs can selectively inhibit gene expression at the transcriptional level or repair genetic defect by direct genome modification in human cells. These qualities makes TFO potentially powerful therapeutic tool for gene repair and/or expression regulation.

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19

Kolokoltseva, E. V. "Mass Media As Forming Public Opinion Tool." Contemporary problems of social work 3, no. 3 (June 27, 2017): 74–81. http://dx.doi.org/10.17922/2412-5466-2017-3-3-74-81.

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20

ten Thije, R. H. W., R. Akkerman, L. van der Meer, and M. P. Ubbink. "Tool-ply friction in thermoplastic composite forming." International Journal of Material Forming 1, S1 (April 2008): 953–56. http://dx.doi.org/10.1007/s12289-008-0215-9.

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21

Alves, L. M., and P. A. F. Martins. "Flexible forming tool concept for producing crankshafts." Journal of Materials Processing Technology 211, no. 3 (March 2011): 467–74. http://dx.doi.org/10.1016/j.jmatprotec.2010.10.024.

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22

Andersson, A. "Comparison of sheet-metal-forming simulation and try-out tools in the design of a forming tool." Journal of Engineering Design 15, no. 6 (December 2004): 551–61. http://dx.doi.org/10.1080/09544820410001697598.

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23

Giedenbacher, Jochen, Anna Elisabeth Raab, Christian Walch, and Aziz Huskic. "The Quantification of Galling in Forming Operations of Hot Dip Galvanized Sheet Metal under Laboratory Conditions." Materials Science Forum 879 (November 2016): 607–12. http://dx.doi.org/10.4028/www.scientific.net/msf.879.607.

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In the sheet metal forming industry, tools are subject to mechanical, thermal, chemical and tribological loads. One of the major problems in forming operations of hot-dip galvanized sheet metal is galling (build-up of zinc flakes on the tool). This phenomenon develops gradually as an adhesion on the tool surface. The adhesive wear leads to high rejection and reworking costs for large car body forming tools. Due to economic aspects and the easy castability, the forming tools are made of cast iron. These materials tend to high adhesive wear. The aim of this project is to find a three-dimensional surface parameter, which describes a tribologically advantageous surface of forming tools in order to reduce galling. An additional objective is to optimize tool materials, heat treatment and surface coating. The evaluation of galling under laboratory conditions is based on strip drawing tests. The characterization of tool materials was executed for grey cast iron (EN-GJL-200/250) and nodular cast iron (EN-GJS-700). Investigations demonstrate that the processing methods and test parameters like sliding speed and temperature have a significant influence on galling. Three-dimensional surface parameters have also shown an effect on galling.

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24

Meier, Horst, and Christian Magnus. "Incremental Sheet Metal Forming with Direct Resistance Heating Using Two Moving Tools." Key Engineering Materials 554-557 (June 2013): 1362–67. http://dx.doi.org/10.4028/www.scientific.net/kem.554-557.1362.

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This paper describes new developments in an incremental, robot-based sheet metal forming process (‘Roboforming’) for the production of sheet metal components in small batch sizes. The dieless kinematic-based generation of a shape is implemented by means of two industrial robots which are interconnected to a cooperating robot system. Compared to other incremental sheet metal forming machines, this system offers high geometrical form flexibility without the need of any part-dependent tools. The industrial application of incremental sheet metal forming is still limited by certain constraints, e.g. the low geometrical accuracy and number of formable alloys. One approach to overcome the stated constraints is to use the advantages of metal forming at elevated temperatures. For the temperature input into the sheet metal, there are different approaches like heating with warm fluids, a laser beam or using direct resistance heating. This paper presents results of the research project ‘Local heating in robot-based incremental forming’, funded by the German Research Foundation (DFG), where the heating of the current forming zone by means of direct resistance heating is examined as a variation of the Roboforming process. In order to achieve a local limitation of the heating on the current forming zone, the electric current flows into the sheet at the electric contact of the forming tool and the sheet metal. Thus the forming tool is part of the electric circuit. In current literature Authors report about results from experiments using single-point incremental forming, where the forming tool and the clamping frame of the sheet are connected to the power source. In order to further limit the heating on the forming zone, a new approach will be presented in this paper, where a second tool is used to support the forming and heating process, as both tools can be connected to the power source, making a current flow through the rest of the sheet and the clamping frame unnecessary. With the use of two tools the current flow and thus the heated zone of the sheet can be manipulated. Additionally the advantages of the supporting tool, already shown in forming at room temperature, such as increased geometrical accuracy and maximum draw angle can be used. Starting with a description of the new process setup for steel forming at about 600 °C, results of experiments evaluating the influence of the supporting tool on the forming process at elevated temperatures and the resulting geometrical accuracy will be presented in this paper. Therefore, different process parameters as forming temperature, cooling and relative positioning of the both tools have been varied.

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25

Müller, Roland, and André Mosel. "Characterisation of Tool Coatings for Press Hardening." Advanced Materials Research 966-967 (June 2014): 259–69. http://dx.doi.org/10.4028/www.scientific.net/amr.966-967.259.

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Hot sheet metal forming is gaining in importance in many fields, because of its capability to produce more complex components than possible with cold forming. Hot forming is also used to influence the final material properties with the hot forming of manganese-boron steels being a good example. One of the major challenges in hot forming is the tribological conditions between the tool and sheet material at the required high temperatures. This article will discuss the influence of different tool material coatings, ranging from PVD to mechanically bonded ceramic coatings, on the tribological conditions during forming. It will also shed light on how these coatings influence the heat transfer between the component ́s material and the tool material.

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26

Braeuer, Guenter, Hanno Paschke, Martin Weber, Bernd Arno Behrens, and Timur Yilkiran. "Surface Modifications for Optimized Forming Operations." Key Engineering Materials 611-612 (May 2014): 231–39. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.231.

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During forming operations the contact conditions relating to the surface of the tools, the intermediate coolant or lubricant and the hot work piece material are determining the material flow and the resulting wear. The possibilities for an optimization of the tool surfaces are aspects of various scientific activities of IST and IFUM and are subject of this paper. Tools typically made of hot working steel can be treated with different technologies in order to achieve wear resistant properties. First of all, the surface is mainly determined by its topography which is defined by the manufacturing method or applied finishing technology. This paper will give an overview to adjustable surface properties with additional conditioning methods like severe shot peening. The stabilization of the topography is a new approach to enhance the wear resistance of forming tools. Several models like the Abbott-Firestone graph are used in order to obtain suitable describing parameters such as the roughness-parameter sk. The development of skduring the running-in stage has a strong influence on the tool life which can be shown. A stabilization of the topographical conditions can enhance the service life of the tools. It will be shown, that this is possible by applying plasma diffusion treatments and thin film coatings by means of vacuum coating technologies.

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27

Otsu, Masaaki, Yosuke Katayama, and Takayuki Muranaka. "Effect of Difference of Tool Rotation Direction on Forming Limit in Friction Stir Incremental Forming." Key Engineering Materials 622-623 (September 2014): 390–97. http://dx.doi.org/10.4028/www.scientific.net/kem.622-623.390.

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An effect of tool rotation direction on forming limit in friction stir incremental forming was studied. A 3-axes NC milling machine and a hemispherical tool which with a diameter of 6 mm made of high speed steel was used for forming. The thickness of commercial A5052-H34 aluminum sheet was 0.5 mm. The forming tool was moved from the outside to inside in a pitch of 0.5 mm spirally, and the sheets were formed into frustum of pyramid shape. Formability evaluated by minimum wall angle of the pyramid was investigated by changing a tool rotation rate, tool feed rate and tool path direction. When the tool paths were clockwise and counter clockwise, they were defined to “advancing direction” and “retreating direction” as well as in friction stir welding, respectively. From the experimental results, forming limits by both rotation directions of advancing and retreating were almost the same, however, the range of formable working conditions in advancing direction was slightly wider than that in retreating direction. Evaluating the forming limits in relative velocity between the tool surface and the sheet, no difference of forming limit was obtained between forming in advancing direction and retreating directions.

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28

Baptista, Rui, M. Beatriz Silva, and Carlos Saraiva. "Developments for Rapid Tooling Application in Sheet Metal Forming." Materials Science Forum 514-516 (May 2006): 1516–20. http://dx.doi.org/10.4028/www.scientific.net/msf.514-516.1516.

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The market is changing very quickly, demanding the companies the capability of producing better and/or more performing products. This changing market leads the companies to be more flexible and agile. In particular, for the tool makers and the stamping companies, they are requested to participate in the design phase of the product and process, as well as to produce prototypes and small series in very short time and with low costs. To answer to these demands in the stamping steps design and consequently in the tool design, several finite elements packages are widely used, allowing the tool designers to foresee the results of their options/decisions without the need to manufacture and test tools, with the inherent excessive cost of money and time. Following this methodology, CAE analysis, the final phase of tool try out, always necessary, will be certainly shorter and less expensive, once they start with a solution quite more worked and, for sure, closer to the final solution. In this industrial context, appeared the great motivation for the development of competences on the rapid manufacturing of stamping tools (active elements: punch, die and blankholder), on the numerical simulation of the process and, on the development of the modular tool concept. In this paper the main results of the development of these areas of research, are presented. In particular, the use of the numerical simulation, using PAM-STAMP 2G software, for the validation of the stamping phases, the realisation of laboratorial stamping tests using tools produced by the several techniques available on Portugal for rapid prototyping. At the same time, it was developed the modular tool concept, i.e., a tool in which by fast and easy change of the active elements, different parts can be formed. The active elements of the tool have been manufactured by several rapid tooling techniques, like DMLS - Direct Metal Laser Sintering, LOM - Laminate Object Manufacturing, HSM – High Speed Milling and also the machining of non-traditional materials such as nylon, ureol and aluminium. Some inserts have been produced by indirect techniques such as reinforced resins (polyurethane, epoxy and urethane) using shells produced by SLstereolithography. Finally some conclusions are drawn.

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29

Dien, Le Khanh, Nguyen Van Thanh, and Nguyen Tan Hung. "A research on a new structure of forming tool in Single Point Incremental Forming (SPIF)." Science & Technology Development Journal - Engineering and Technology 3, SI1 (August 17, 2020): SI157—SI163. http://dx.doi.org/10.32508/stdjet.v3isi1.757.

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Single Point Incremental Forming (SPIF) is really a new technology of forming metal sheet nowadays and in recent decades. Although it was invented in, 1967 by Lezak, an American inventor, but the applications of the innovative technology were broad from 1990 because of the advance of controlling technology. This technology is especially adapted to small batch, unique or single productions. There are many forming parameters that influence to the formability of the metal sheet workpiece such as diameter of tool, the revolution per minute of the tool tip, the vertical feed rate after each orbit, the velocity of tool in horizontal plane…. Among of them, in our own experiences, we recognize that in almost all cases, the revolution per minute of the forming tool when forming ferric material sheet such as mild steel, stainless steel, hard steels… should be as small as possible to get the biggest ability of deformation of the workpiece sheet to get rid of failure on the lateral edge of the sheet. The tangential velocity of forming point on the spherical tool tip should be selected to attain the situation of rolling but no sliding of the surface of the spherical tool on the one of the sheet material. The paper recommends a new version of a forming tool in which the tip of the tool is a very hard ball (such as the quenched ball in a ball bearing) that is freely rotate by the friction to modify the contact point on the spherical surface of the tool to avoid the abrading and keep the spherical shape and the situation of rotating but no sliding on the surface of the workpiece sheet as mentioned above. The manufacture of the innovative forming tool is performed and then empirical processes verified it. The models formed by the typical tool are better in comparison with the ones of normal forming tool.

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30

Jeswiet, J., David J. Young, and M. Ham. "Non-Traditional Forming Limit Diagrams for Incremental Forming." Advanced Materials Research 6-8 (May 2005): 409–16. http://dx.doi.org/10.4028/www.scientific.net/amr.6-8.409.

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Although not standard, Forming Limit Diagrams, FLD’s, are used throughout the automotive industry as a preliminary tool to determine if a sheet metal forming process is capable of forming a good part. FLD’s show a limited range of strains on the diagram; typically the range is 0 to 1 on the major strain axis. A new rapid prototyping process called Single Pont Incremental Forming, SPIF, experiences strains over 3. As FLD’s do not typically cover that level of strain, a new method for developing FLD’s is needed. Such a method is proposed in this paper. Research has been conducted with five different shapes, formed using Single Point Incremental Forming. The part shapes utilized contain the most common combinations of angles and curves observed in formed sheet metal products. The strains encountered in forming each of these parts are measured and the strain data is then plotted on the same FLD. These new FLD’s can then be utilized as a predictive tool for engineers to determine if their design can be produced using the SPIF process.

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Hundt, Tobias, Carsten Schmidt, Berend Denkena, Kevin Engel, and Peter Horst. "Variable Forming Tool and Process for Thermoset Prepregs with Simulation Verified Part Quality." Key Engineering Materials 611-612 (May 2014): 391–98. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.391.

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In this paper a new variable forming tool concept and associated numerical methods for calculating optimal actuator layout and estimating CFRP part quality are presented. The concept of the tool features a modular design and active control of the forming process to achieve the desired geometry. Initially the laminate is placed on the flat top layer of the forming tool. There it is fixed and compacted using vacuum bagging. After compacting, it is heated up to increase the performance of the forming process using water based tempering of the forming tools top layer. The heated laminate is then formed, pulling the tools top layer into the desired geometry using the actuators. Finally, the formed laminate is cooled and transferred into a mold for curing. The position of the forming tools actuators on the base plates is variable. Numerical optimization in combination with finite element (FE) technologies is utilized, to approximate the tool surface within given error margins, with as few actuators as possible. In addition, results of a numerical method for part quality estimation are shown. The influence of the forming process on mechanical properties due to fiber waviness is taking into account using a self-developed method that includes manufacturing characteristics in FE modeling of the part. The method is based on mathematical descriptions of fiber waviness, which are implemented into a FE model. Therefore a structure discretization assuming perfect fiber orientations is realized and the expected fiber waviness induced by the forming process is applied element-wise.

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Abdupattoev, Mukhammadtokhir Tojimamatovich. "Unusual Connections As Forming Literary Text." American Journal of Social Science and Education Innovations 03, no. 02 (February 27, 2021): 177–82. http://dx.doi.org/10.37547/tajssei/volume03issue02-28.

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This article examines the role of the unusual connection in the formation of the literary text, which is a type of unusual connection in the Uzbek language. It has also been analyzed using examples that this tool is also a means of emotional expression in a literary text.

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Pujante, Jaume, Borja González, and Eduard Garcia-Llamas. "Pilot Demonstration of Hot Sheet Metal Forming Using 3D Printed Dies." Materials 14, no. 19 (September 30, 2021): 5695. http://dx.doi.org/10.3390/ma14195695.

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Since the popularization of press hardening in the early noughties, die and tooling systems have experienced considerable advances, with tool refrigeration as an important focus. However, it is still complicated to obtain homogeneous cooling and avoid hot spot issues in complex geometries. Additive Manufacturing allows designing cavities inside the material volume with little limitation in terms of channel intersection or bore entering and exit points. In this sense, this technology is a natural fit for obtaining surface-conforming cooling channels: an attractive prospect for refrigerated tools. This work describes a pilot experience in 3D-printed press hardening tools, comparing the performance of additive manufactured Maraging steel 1.2709 to conventional wrought hot work tool steel H13 on two different metrics: durability and thermal performance. For the first, wear studies were performed in a controlled pilot plant environment after 800 hot stamping strokes in an omega tool configuration. On the second, a demonstrator tool based on a commercial tool with hot spot issues, was produced by 3D printing including surface-conformal cooling channels. This tool was then used in a pilot press hardening line, in which tool temperature was analyzed and compared to an equivalent tool produced by conventional means. Results show that the Additive Manufacturing technologies can be successfully applied to the production of press hardening dies, particularly in intricate geometries where new cooling channel design strategies offer a solution for hot spots and inhomogeneous thermal loads.

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Cho, C., and Y. J. Kim. "Study on forming condition and tool of flywheel by using flow forming process." Materials Research Innovations 15, sup1 (February 2011): s336—s339. http://dx.doi.org/10.1179/143307511x12858957674599.

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Park, Ji-Woo, Tae-Wan Ku, Jeong Kim, Kwang-Ho Kim, and Beom-Soo Kang. "Tool fabrication for composite forming of aircraft winglet using multi-point dieless forming." Journal of Mechanical Science and Technology 30, no. 5 (May 2016): 2203–10. http://dx.doi.org/10.1007/s12206-016-0428-7.

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Dubovská, Rozmarína, and Jozef Majerik. "Modeling and Virtual Simulation of Hard Surface Milling and Forming Process Using Advanced CAE Systems." Advanced Materials Research 941-944 (June 2014): 2321–31. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.2321.

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This paper presents the influence of modeling and simulation techniques for hard milling and forming. The aim of these simulations is the ability to optimize the manufacturing technologies even before the real production of its own tools, because their manufacturing process is very difficult in terms of production time, materials and other costs. The simulated results visualize roughing and finishing process of milling and generate tool-paths in CATIA V5. Simulation results of forming realized in PAM-Stamp 2G using a 3D model of the punch and the blank confirm the suitability of the proposed design of the forming tool. Finally, hard milling and forming simulations in CAE systems CATIA V5 and PAM-Stamp 2G were performed in order to determine and evaluation of suitability of the proposed shapes of the forming tool.

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Aksenov, L. B., and I. Y. Kononov. "Thin Sheet Forming with 3D Printed Plastic Tool." Solid State Phenomena 299 (January 2020): 705–10. http://dx.doi.org/10.4028/www.scientific.net/ssp.299.705.

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The prospects of 3D printed plastic tooling in the processing of metal forming are shown. The study of the process of thin sheet, forming of aluminum 3003 ANSI, established that in this process the destruction and plastic deformation of the plastic tool does not occur. Lubrication of plastic matrices and punches were not required, as they have anti-friction properties. Computer simulation of this process in the software system "Simufact.forming" accurately reflects the force parameters, stress-state of plastic tool and the actual course of the process of forming the blank, including the spring-back of the part after forming. Technology of sheet forming with plastic tool can be recommended for single and small batch production.

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Tröber, Philipp, Markus Welm, Hannes Alois Weiss, Peter Demmel, Roland Golle, and Wolfram Volk. "The influence of process parameters on the temperature development in the forming zone." MATEC Web of Conferences 190 (2018): 14004. http://dx.doi.org/10.1051/matecconf/201819014004.

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Cold metal forming is a fast and economical way of producing a wide range of precise components. Its profitability mainly depends on part quality, process stability and service intervals of tools. As these factors are all determined by tool wear, detailed process knowledge is indispensable to maximize profitability by minimizing wear. One of the most crucial factors in this context is temperature. During every forming process, a temperature rise occurs between tool and workpiece due to frictional heating and a large part of plastic work dissipating into heat. This temperature affects the whole forming process but especially tool wear. Currently, there is little solid information about temperatures occurring during forming operations. Therefore, the temperature was measured based on varying process parameters in several embossing and blanking examinations. The use of a tool-workpiece-thermocouple enabled accurate and instantaneous measurement during the process. The results presented show the strong influence of process parameters on temperatures in the forming zone.

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Tröber, Philipp, Markus Welm, Hannes Alois Weiss, Peter Demmel, Roland Golle, and Wolfram Volk. "The influence of process parameters and sheet material on the temperature development in the forming zone." Manufacturing Review 6 (2019): 9. http://dx.doi.org/10.1051/mfreview/2019005.

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Cold metal forming is a fast and economical way of producing a wide range of precise components. Its profitability mainly depends on part quality, process stability, and service intervals of tools. As these factors are all determined by tool wear, detailed process knowledge is indispensable to maximize profitability by minimizing wear. One of the most crucial factors in this context is temperature. During every forming process, a temperature rise occurs between tool and workpiece due to frictional heating and a large part of plastic work dissipating into heat. This phenomenon affects the whole forming process but especially tool wear. Currently, there is little solid information about temperatures occurring during forming operations. Therefore, the temperature was measured based on varying process parameters, sheet materials, and thicknesses in several embossing and blanking examinations. The use of a tool–workpiece thermocouple enabled accurate and instantaneous measurement during the process. The results presented show the strong influence of process and material parameters on temperatures in the forming zone.

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Mynors, Diane J., Martin English, and Michael Castellucci. "Automating the Design of Cold Roll Forming Roll Sets." Key Engineering Materials 410-411 (March 2009): 227–33. http://dx.doi.org/10.4028/www.scientific.net/kem.410-411.227.

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The design of cold roll forming roll tools, roll geometry and the number of tool sets, can typically be referred to as experiential design. Within a multi-occupant design office there will normally, for the same sectional profile, be as many different designs as there are designers. This variation in design results in a lack of design consistency and hence makes the process of developing design understanding, increasing profile complexity, maintaining quality, and roll tool predictability very difficult. This paper contains an explanation of the approach taken within the Hadley Group to identify the discrete steps associated with roll tool set design. To implement methods to standardise these steps including strip width and clearance calculations. With appropriate design steps standardised an explanation is provided as to how elements of this design process is automated leading to a system of assisted design for roll tool sets. The results, including increased design capacity, of the assisted roll design after being incorporated into the design office are discussed.

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Sieczkarek, Peter, Lukas Kwiatkowski, A. Erman Tekkaya, Eugen Krebs, Dirk Biermann, Wolfgang Tillmann, and Jan Herper. "Improved Tool Surfaces for Incremental Bulk Forming Processes of Sheet Metals." Key Engineering Materials 504-506 (February 2012): 975–80. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.975.

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Sheet-bulk metal forming is a process used to manufacture load-adapted parts with high precision. However, bulk forming of sheet metals requires high forces, and thus tools applied for the operational demand have to withstand very high contact pressures, which lead to high wear and abrasion. The usage of conventional techniques like hardening and coating in order to reinforce the surface resistance are not sufficient enough in this case. In this paper, the tool resistance is improved by applying filigree bionic structures, especially structures adapted from the Scarabaeus beetle to the tool’s surface. The structures are realized by micromilling. Despite the high hardness of the tool material, very precise patterns are machined successfully using commercially available ball-end milling cutters. The nature-adapted surface patterns are combined with techniques like plasma nitriding and PVD coating, leading to a multilayer coating system. The effect of process parameters on the resistance of the tools is analyzed experimentally and compared to a conventional, unstructured, uncoated, only plasma nitrided forming tool. Therefore, the tools are used for an incremental bulk forming process on 2 mm thick metal sheets made of aluminum. The results show that the developed methodology is feasible to reduce the process forces and to improve the durability of the tools.

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HAYAKAWA, Kunio. "Workpiece-Tool Coupled Analysis on Bulk Forming Process." Journal of the Japan Society for Technology of Plasticity 57, no. 661 (2016): 90–94. http://dx.doi.org/10.9773/sosei.57.90.

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Neugebauer, Reimund, Verena Psyk, and Christian Scheffler. "A Novel Tool Design Strategy for Electromagnetic Forming." Advanced Materials Research 1018 (September 2014): 333–40. http://dx.doi.org/10.4028/www.scientific.net/amr.1018.333.

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To make the advantages of electromagnetic forming applicable for industrial manufacturing, a three step tool design strategy is suggested. At first, simplified decoupled electromagnetic and structural mechanical simulations are used for creating a preliminary design via a systematic iterative optimization process. The selected design is verified in more accurate coupled simulations. A prototypic realization serves for further optimization, if necessary. The applicability of the approach is proved on the basis of an inductor system for magnetic pulse welding of tubes.

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44

Bagudanch, Isabel, Rogelio Pérez-Santiago, and Maria Luisa García-Romeu. "Tool Path Strategies for Single Point Incremental Forming." Key Engineering Materials 473 (March 2011): 905–12. http://dx.doi.org/10.4028/www.scientific.net/kem.473.905.

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In the last few years the interest in Incremental Sheet Forming (ISF) has considerably grown due to the possibility of obtain small production batches and high customized products. Despite the increasingly knowledge of this processing technique, there are still some important process parameters that require further development. One of the most important parameters when experimental or numerical studies of ISF are carried out is the tool path programming. The decision of the strategy that will be followed can affect the accuracy, the surface finishing, the forming forces, etc. The analysis of these relationships has been studied for several authors using different tool path. In the present paper different tool path strategies for the same geometry are compared. The geometry has two inclination wall angles. Also, different commercial softwares are employed to develop the tool path of the desired geometry. The main objective of the paper is to identify some indicators that can assist in the choice of which strategy is the best, not only depending on the complexity of the geometry or the software used but also on qualitative criteria. With all this work it is possible to provide some useful guidelines that permit to establish a selection criterion of the tool path, which will be very interesting before developing an experimental work.

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Jiang, Wei, Takuya Miura, Masaaki Otsu, Masato Okada, Ryo Matsumoto, Hidenori Yoshimura, and Takayuki Muranaka. "Development of Penetrating Tool Friction Stir Incremental Forming." MATERIALS TRANSACTIONS 60, no. 11 (November 1, 2019): 2416–25. http://dx.doi.org/10.2320/matertrans.p-m2019841.

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46

Martínez-Romero, Oscar, María Luisa García-Romeu, Daniel Olvera-Trejo, Isabel Bagudanch, and Alex Elías-Zúñiga. "Tool Dynamics During Single Point Incremental Forming Process." Procedia Engineering 81 (2014): 2286–91. http://dx.doi.org/10.1016/j.proeng.2014.10.322.

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47

Durgun, Ismail. "Sheet metal forming using FDM rapid prototype tool." Rapid Prototyping Journal 21, no. 4 (June 15, 2015): 412–22. http://dx.doi.org/10.1108/rpj-01-2014-0003.

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Purpose – The purpose of this paper is to investigate usage of fused deposition modeling (FDM)-based sheet metal tooling for small lot productions as a real case. FDM-based sheet metal tooling was used for stamping prototype parts for two different materials to evaluate dimensional conformance. Design/methodology/approach – The experimental process of data capture used the following steps: sheet metal parts were stamped and optically scanned at every 10th interval for both DC04 and S355MC material. FDM-based upper and lower dies were optically scanned at 1st, 51st and 101st intervals. Dimensional conformance analyses were carried out by using scanned data to evaluate the behavior of FDM dies against DC04 and S355MC materials in terms of geometric deviation. Findings – Satisfactory results were obtained for DC04 material by using FDM-based tooling, and overall deviation was at an acceptable level in terms of production tolerance. S355MC material is harder than DC04 and results were not convenient in terms of tolerance range. Geometric deviation of FDM dies was slightly increased and after the 50th part, increased drastically due to squeezing of FDM layers. Experiments showed that this method can be used for DC04 material and up to 100 parts can be stamped within the tolerance range. Using FDM-based sheet metal tooling, product development phase can be shortened in terms of leading time. Originality/value – This paper presents a study to create an alternative tooling method to shorten product cycle and product development phase by integrating rapid tooling methods to low-volume production.

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OTSU, Masaaki, Seiya ICHIKAWA, and Takayuki MURANAKA. "501 Friction stir incremental forming with inclined tool." Proceedings of the Materials and processing conference 2013.21 (2013): _501–1_—_501–4_. http://dx.doi.org/10.1299/jsmemp.2013.21._501-1_.

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Thiruvarudchelvan, S. "A urethane clamp as a metal-forming tool." Journal of Materials Processing Technology 38, no. 3 (May 1993): 491–500. http://dx.doi.org/10.1016/0924-0136(93)90065-e.

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50

Oraon, Manish. "Tool wear in the single point incremental forming." Materials Today: Proceedings 56 (2022): 1738–42. http://dx.doi.org/10.1016/j.matpr.2021.10.454.

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