Enhancement of accuracy in double sided incremental forming by compensating tool path for machine tool errors
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ORIGINAL ARTICLE
Enhancement of accuracy in double sided incremental forming by compensating tool path for machine tool errors P. Konka 1 & R. Lingam 1 & U. A. Singh 1 & CH. Shivaprasad 1 & N. V. Reddy 1 Received: 21 August 2020 / Accepted: 23 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Incremental Sheet Forming (ISF) is a dieless forming process and has capability to form complex 3D geometries. Double Sided Incremental Forming (DSIF) is the most flexible variant of ISF as it uses two tools, one on either side of the sheet (one tool forms the sheet and other acts as support). However, forming the components with acceptable accuracy is one of the challenges as it depends on many factors such as sheet and tool(s) deflections as well as machine tool errors. If these deflections/deviations are not compensated in tool path, accuracy of the component gets affected and support tool may lose contact or squeeze the sheet while forming components. In the present work, grid-based method is used to measure the machine tool error at discrete points of the work envelope. To enhance the accuracy and support tool contact condition, machine tool errors are compensated in tool path along with tool and sheet deflection compensations developed earlier. To demonstrate the effectiveness of developed methodology on the accuracy, components having different geometric characteristics as well as opening sizes are formed with and without compensating for machine tool errors in tool path. Results indicate that deviation in symmetry within the same contour reduced from 850 μm to less than 40 μm. In addition, support tool has maintained contact throughout support surface with maximum force of 50 N when machine tool errors are compensated. Keywords Double sided incremental forming . Machine tool errors . Accuracy . Compensated tool path
1 Introduction Incremental Sheet Forming (ISF) process has the capability to form complex 3D geometries without component specific tooling. In this process, a sheet metal is clamped along its periphery and simple tool(s) moving in a predefined path progressively deforms the sheet to required geometry. Advantages of ISF process include higher formability, less lead time and suitability for low volume production [1–5]. The simple variant of ISF, Single Point Incremental Forming (SPIF), uses single tool to form the geometry from one side of sheet without any support from other side as shown in Fig. 1a [6–12]. Hence, the components formed using SPIF have a significant amount of bending at component opening P. Konka and R. Lingam contributed equally to this work. * N. V. Reddy [email protected] 1
Department of Mechanical and Aerospace Engineering, Indian Institute of Technology Hyderabad, Kandi, Sangareddy, Telangana 502 285, India
[2, 3, 12]. The most flexible variant of ISF, Double Sided Incremental Forming (DSIF) process, uses two tools, one each on either side of the sheet (Fig. 1b). At any instant, one tool forms the work piece and other provides local support [13–25]
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