Descripció del projecte
An alternative route to producing high surface-to-thickness products is represented by incremental sheet forming (ISF) processes, which have great potential in the aeronautic, medical and automotive sectors. In ISF, the periphery of the sheet metal is clamped, while the material is locally deformed by one, i.e., single point incremental forming (SPIF), or more stylus tools that move along pre-defined tool paths. Therefore, because of their dieless nature and high flexibility, these techniques are most suitable when low-volume customized sheet metal parts have to be manufactured. To improve the final geometric accuracy achievable with SPIF, different variants of the ISF process have emerged, such as multipass incremental forming covering the entire or partial forming areas repeatedly, and double-sided incremental forming (DSIF). The challenge in the incremental forming techniques is forming workpieces made of lightweight but difficult-to-form materials. Because of its limited formability at room temperature and its good mechanical properties, a possible solution to form some sheet metals using ISF processes is to increase the forming temperature.
Therefore, in this project, we are going to develop and refine the Double-Sided Incremental Forming technology by using a hybrid solution (including different sources of temperature) and trying to implement a force control force to ensure contact during the plastic deformation process. Our project adopts a comprehensive thermomechanical approach, delving into the intricate interplay between forming forces, final geometry, localized deformation and temperature. We are committed to characterizing the hybrid DSIF process in its entirety, going beyond basic assessments to include thorough analyses of surface roughness, metallography observations, and material hardness. This multifaceted examination aims to unravel all the involved parameters and provide a holistic understanding of the DSIF technique. To do that, the use of numerical simulations is a crucial tool in defining strain in the pinch area and evaluating residual stresses—both intricately linked to fracture behavior. The thermal adjustments introduced by DSIF play a pivotal role in stress release within the affected area, resulting in improved material formability, heightened surface roughness, and the preservation of material microstructure.
Finally, this project is not merely an academic pursuit to publish scientific articles and assist conferences; it represents a transformative solution poised to elevate the fabrication of complex components in the critical industrial sector of metal-forming. For this reason, we will integrate conventional sheet metal stamping companies in the development to test the manufacturing limits and who may be interested in developing the technology on an industrial scale in the future.