Presentación de deformación incremental de chapa

1. Incremental Sheet Forming
Kathryn Jackson
1st December 2005

2. Overview
• What is ISF?
• Why is ISF potentially very useful?
• Why is ISF not more widely applied already?
• What are my research projects?

3. 1. What is ISF?

4. Incremental sheet forming (ISF) is
metal forming by a progression of
localised deformation
y
z
x

5. Tooling and Workpiece Support

6. 2. Why is ISF potentially very
useful?

7. Why sheet metal forming?
Why sheet metal forming?
• A practical way to form a thin 3D shell
Why sheet metal forming?
• Metal properties are desirable for many
applications

8. Sheet Metal Applications

9. Why choose ISF over other sheet metal
forming processes?
Deep drawing
Spinning
Flow forming
Pressing
Stamping
Peen forming
Incremental sheet forming
Hydroforming Laser forming

10. Evaluation of ISF
Mechanical Ecological
Economic

11. Mechanical Evaluation of ISF
Max Requirement
Min Requirement
Maximum dimension 20mm 5m
Geometric tolerance 0.5mm 5mm
Minimum feature radius 1mm 50mm
Surface finish ‘Very good’
‘good’
Wall angle 90o
0o
Sheet thickness 0.4mm 3mm
Mechanical evaluation shows overlap of process window with typical
requirements is good

12. Economic Evaluation of ISF
Cost per product or speed
per product
Processes requiring dies
(stamping, deep drawing)
Incremental sheet forming
Batch size
~200 to 1200 parts
Economic viability for small batch sizes

13. Economic Evaluation of ISF
Possible Applications
Personalisation
Decorative
Repair/replacement
Industrial
Medical
Architectural

14. Ecological Evaluation of ISF
Energy savings Materials
savings
✔ ✔
No die required
✔
Localised production –
reduction of transportation
✔ ✔
Reworking instead of
reprocessing or scrapping
✔
Lower forming forces
✔ ✔
Smaller machines
ISF has strong ecological advantages

15. Summary of Evaluation
ISF is potentially a very useful sheet metal
forming process….
….But there is hardly any application in
industry already

16. 3. Why is ISF not more widely
applied already?

17. Why?
In reality the ‘optimum’ mechanical capabilities are
usually not achieved

18. Major Challenges for ISF
• There is a complicated interaction between the
process design and process capabilities, which
means the process is usually not optimised
• Accuracy relies on complicated tool path
optimisation or expensive workpiece support
• Machinery and tooling design restrict the ‘design
space’
• Not well known

19. 4. What are my research
projects?

20. ISF Research at the IfM
4. Flexible support of the workpiece
1. Tool force and geometry prediction
y
z
x
5. Design of the ‘ideal’ incremental sheet
2. Sandwich panel forming
forming machine
3. Real time process control using
force feedback

21. Thank you!