Research On The Incremental Sheet Edge Forming Process And Characteristics

Incremental sheet forming utilizes a simple forming tool rather than die to gaincomplicated shape components, which is called as a flexible dieless process. Thisthesis had discussed and analyzed tool path, material original thickness and frictiontype on the effect of incremental hole-flanging process. Besides, comparative study onconical hole-flanging of sheet metal by conventional die and incremental formingprocess had been performed. Comparison experiments were designed to get the effectof tool path, original sheet thickness, friction type and utilizing conventional die andincremental forming process to perform hole-flanging had been carried outexperimental study. After that, a new coaxial cutter aligner equipment was developedto satisfy tool setting and accomplish hole-flanging on complicated surface. The mainresearch results are as follows:1) The deformation of hole-flanging by incremental sheet forming was acombination of in-plane shearing with bending around the perimeter of the flange,therefore the sine law cannot be used to estimate the final thickness of component.2) Conical hole-flanging component by incremental forming had a thinnest placein the intermediate stage rather than the edge of hole, compared with conicalhole-flanging component by conventional die; In comparison to conventional die, holeexpanding rate increased by24.4%in incremental forming.3) The relationship between original sheet thickness and flatness on flange edgebased on special tool path was built up.4) Innovative axial cutter aligner was developed to accomplish hole-flanging onspherical surface and half tube to prove the validation of the equipment.