A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

Incremental Sheet Forming (ISF) is emerging as one of the popular dieless forming processes for the small-sized batch production of sheet metal components. However, the parts formed by the ISF process suffer from poor surface finish, geometric inaccuracy, and non-uniform thinning, which leads to poo...

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Autores principales:	Harshal Y. Shahare, Abhay Kumar Dubey, Pavan Kumar, Hailiang Yu, Alexander Pesin, Denis Pustovoytov, Puneet Tandon
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	incremental sheet forming hammering aluminum alloy incremental sheet hammering Mining engineering. Metallurgy TN1-997
Acceso en línea:	https://doaj.org/article/3bd00547dcdf439091684df78567fb70
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spelling	oai:doaj.org-article:3bd00547dcdf439091684df78567fb702021-11-25T18:22:29ZA Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets10.3390/met111118622075-4701https://doaj.org/article/3bd00547dcdf439091684df78567fb702021-11-01T00:00:00Zhttps://www.mdpi.com/2075-4701/11/11/1862https://doaj.org/toc/2075-4701Incremental Sheet Forming (ISF) is emerging as one of the popular dieless forming processes for the small-sized batch production of sheet metal components. However, the parts formed by the ISF process suffer from poor surface finish, geometric inaccuracy, and non-uniform thinning, which leads to poor part characteristics. Hammering, on the other hand, plays an important role in relieving residual stresses, and thus enhances the material properties through a change in grain structure. A few studies based on shot peening, one of the types of hammering operation, revealed that shot peening can produce nanostructure surfaces with different characteristics. This paper introduces a novel process, named the Incremental Sheet Hammering (ISH) process, i.e., integration of incremental sheet forming (ISF) process and hammering to improve the efficacy of the ISF process. Controlled hammering in the ISF process causes an alternating motion at the tool-sheet interface in the local deformation zone. This motion leads to enhanced material flow and subsequent improvement in the surface finish. Typical toolpath strategies are incorporated to impart the tool movement. The mechanics of the process is further explored through explicit-dynamic numerical models and experimental investigations on 1 mm thick AA1050 sheets. The varying wall angle truncated cone (VWATC) and constant wall angle truncated cone (CWATC) test geometries are identified to compare the ISF and ISH processes. The results indicate that the formability is improved in terms of wall angle, forming depth and forming limits. Further, ISF and ISH processes are compared based on the numerical and experimental results. The indicative statistical analysis is performed which shows that the ISH process would lead to an overall 10.99% improvement in the quality of the parts primarily in the surface finish and forming forces.Harshal Y. ShahareAbhay Kumar DubeyPavan KumarHailiang YuAlexander PesinDenis PustovoytovPuneet TandonMDPI AGarticleincremental sheet forminghammeringaluminum alloyincremental sheet hammeringMining engineering. MetallurgyTN1-997ENMetals, Vol 11, Iss 1862, p 1862 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	incremental sheet forming hammering aluminum alloy incremental sheet hammering Mining engineering. Metallurgy TN1-997
spellingShingle	incremental sheet forming hammering aluminum alloy incremental sheet hammering Mining engineering. Metallurgy TN1-997 Harshal Y. Shahare Abhay Kumar Dubey Pavan Kumar Hailiang Yu Alexander Pesin Denis Pustovoytov Puneet Tandon A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets
description	Incremental Sheet Forming (ISF) is emerging as one of the popular dieless forming processes for the small-sized batch production of sheet metal components. However, the parts formed by the ISF process suffer from poor surface finish, geometric inaccuracy, and non-uniform thinning, which leads to poor part characteristics. Hammering, on the other hand, plays an important role in relieving residual stresses, and thus enhances the material properties through a change in grain structure. A few studies based on shot peening, one of the types of hammering operation, revealed that shot peening can produce nanostructure surfaces with different characteristics. This paper introduces a novel process, named the Incremental Sheet Hammering (ISH) process, i.e., integration of incremental sheet forming (ISF) process and hammering to improve the efficacy of the ISF process. Controlled hammering in the ISF process causes an alternating motion at the tool-sheet interface in the local deformation zone. This motion leads to enhanced material flow and subsequent improvement in the surface finish. Typical toolpath strategies are incorporated to impart the tool movement. The mechanics of the process is further explored through explicit-dynamic numerical models and experimental investigations on 1 mm thick AA1050 sheets. The varying wall angle truncated cone (VWATC) and constant wall angle truncated cone (CWATC) test geometries are identified to compare the ISF and ISH processes. The results indicate that the formability is improved in terms of wall angle, forming depth and forming limits. Further, ISF and ISH processes are compared based on the numerical and experimental results. The indicative statistical analysis is performed which shows that the ISH process would lead to an overall 10.99% improvement in the quality of the parts primarily in the surface finish and forming forces.
format	article
author	Harshal Y. Shahare Abhay Kumar Dubey Pavan Kumar Hailiang Yu Alexander Pesin Denis Pustovoytov Puneet Tandon
author_facet	Harshal Y. Shahare Abhay Kumar Dubey Pavan Kumar Hailiang Yu Alexander Pesin Denis Pustovoytov Puneet Tandon
author_sort	Harshal Y. Shahare
title	A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets
title_short	A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets
title_full	A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets
title_fullStr	A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets
title_full_unstemmed	A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets
title_sort	comparative investigation of conventional and hammering-assisted incremental sheet forming processes for aa1050 h14 sheets
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/3bd00547dcdf439091684df78567fb70
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A Comparative Investigation of Conventional and Hammering-Assisted Incremental Sheet Forming Processes for AA1050 H14 Sheets

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