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1. PhD selection Presentation on
Date: 23/12/2020
MECHANICAL ENGINEERING DEPARTMENT
S.V. NATIONAL INSTITUTE OF TECHNOLOGY, SURAT
SURAT, INDIA
Some Studies on Single Point Incremental Sheet Forming Process
By
Mrs. Anjali ME (Mechanical Engineering)
Tuesday, April 5, 2022 1

2. Brief Information:
Course Year Board/University Percentage of Marks
M.E. (Mech. Engg) 2014-2016 University of Pune, India 7.68/10
B.E. (Mech. Engg.) 2009-2014 University of Pune, India 64.67
XII (HSC) 2007-2009 Maharashtra Board 66.67
X (SSC) 2006-2007 Maharashtra Board 73.84
Tuesday, April 5, 2022 2
PG Project Title: Predictive Modeling & Numerical Studies on Single Point
Incremental Forming of Commercial Al Alloy.
Project Location: 1. University of Pune, Maharashtra.
2. Indo-German Tool Room, Aurangabad [Govt. of India]

3. Future Scope in PhD
Tuesday, April 5, 2022 3
Commercialization
aspects using high-speed
technology
Multi-response
optimization using
MADM methods
Study of Planar
Anisotropy
Parametric investigation
of SPIF process
SPIF
Flow of presentation

4. 4
Introduction
Fig. (a) 1/8 scaled model of a Shinkansen bullet train, (b) Ford logo using the F3T
technology [1, 2]
4
Flexibility
Motivation
Heterogeneity
Economical
Production
Versatile
Applications

5. Introduction
Tuesday, April 5, 2022 5
Fig. Mechanism of ISF [Emmens & Vanden
Boogaard 2011]
 B denotes bending,
 S denotes stretching,
 t denotes thickness of the sheet.
 Z denotes incremental depth, R denotes
tool radius.
Mechanism of ISF
5
Working of SPIF Process

6. Gaps in the Literature
 From available literature, it can be summarized that there is limited understanding of the
influence of input process parameters affecting the SPIF performance.
 The relationship between the process parameters with their response have not been well
documented through scientific theory.
 From the available literature, no/limited research work has been found on the planar
anisotropy in the incremental forming process.
 There is limited work has reported on the formability of high strength and low weight
AA5052 H32 alloy by using SPIF.
 Lack of research work was found in improving overall performance of SPIF using Multi-
Objective Optimization techniques.
 It is evident from the reviewed literature that less amount of work has been done so far on
forming execution time though it is a highly essential aspect in the competitive world to
satisfy customer requirements.
Tuesday, April 5, 2022 11

7. Tuesday, April 5, 2022 7
1. Numerical investigation of the
effect of anisotropic plastic
behavior.
2. Study the effect of process
parameters and their interactions
on the performance of SPIF process.
3. To improve the overall
performance of SPIF using Multi-
Objective Optimization
techniques.
4. Performance evaluation of high
speed incremental sheet forming
technology with the principal aim
to commercialize the technology
to shop floor.
Tentative
Research
Objectives
Objectives

8. Tuesday, April 5, 2022 8
1. Effect of Anisotropy on the thickness distribution behavior of SPIF process
Anisotropy is the material property which is directionally dependent.
Motivation
 The uneven thickness distribution and material thinning is one of the major drawback in the
incremental sheet forming process.
 In order to avoid sheet fracturing, the thickness distribution along the depth of specimen is
important factor. However, the factor planar anisotropy may also affect the sheet fracturing
which has not given much attention in the literature. Computer Aided Engineering (CAE)
tools can be used to find the thickness distribution of SPIF parts.
Author Paper Criteria
ESMAEILIZADEH et al.
(2014)
Simulated and experimental investigation of stretch sheet forming of
commercial AA1200 aluminum alloy
Von-Mises and Hills
Fontanari et al. (2012)
NUMERICAL AND EXPERIMENTAL ANALYSIS OF THE SINGLE POINT SHEETS
INCREMENTAL FORMING PROCESS
Hills yield criterion
Jacques et al. (2002)
Anisotropic behaviour law for sheets used in stamping: A comparative study of
steel and aluminium
Hills yield criterion
Fei and Jian-hua (2008)
Numerical simulation and experimental investigation of incremental sheet
forming process
Hills yield criterion
Markus Bambach (2014)
Fast simulation of incremental sheet metal forming by adaptive remeshing and
subcycling
Von Mises criterion

9. Tuesday, April 5, 2022 9
SPIF Performance
(Surface finish and sheet formability)
Forming process
parameters
Material properties
Geometrical parameters
Material
Parameters
Type of
lubricant
Step
depth
Spindle
speed
Feed rate
Sheet
thickness
Tool
diameter
Geometrical
Forming Process
2. Effect of process parameters and their interactions on the performance of SPIF
process.
22

10. Tuesday, April 5, 2022 10
Experimental Work 3 axis CNC vertical milling machine
Z-level tool path with a mixed strategy of tool movement
The reduction in sheet thickness leads to instability point in
the material which causes crack initiation.
High hydrostatic stress developed in the neck region of
specimen leads to catastrophic failure
Fig. Design of the varying wall angle conical frustum with
circular generatrix
Fig. Process flow diagram for the incremental forming of
sheet

11. Tuesday, April 5, 2022 11
3. Multi Response Optimization to enhance overall performance of Incremental
forming process
SPIF
Feed rate
Step depth
Sheet thickness
Tool diameter
Surface Roughness
Forming Time
Sheet thinning
Springback
Single
Response

12. Tuesday, April 5, 2022 12
Title of the Project: Industrial suitability and commercialization of SPIF process for EDD
steel and Titanium materials.
LASER ASSISTED SPIF
increased formability
reduced inaccuracy
reduced process forces
Optimizing the formability and
accuracy achievable with LASPIF
however requires a strategic choice for
the many process parameters involved.

13. Tuesday, April 5, 2022 13
HIGH SPEED SPIF
Formability
Forming Forces
Microstructure and accuracy
Fig. High speed equipment for axisymetric SPIF process (Ambrogio et al. 2013)
The goal of this work is to
investigate the effects that the
increase of the working speed
has on the quality of parts
produced by SPIF.
Objective 4

14. Tuesday, April 5, 2022 14
Objective 5
Material Isotropy Hardening
Exponent
Lubricant
SPIF
Percentage
Stepover
There investigation is limited
to development of empirical
model comprising of these
four process parameters of
ISF.
to/R ratio
Force, stress
Microstructure
thickness
CAE Expt.
Techniques
Expected output

15. PhD work plan
Academic
year
2021 2021-22 2023
Aug. to
Sept.
Oct. to
Nov.
Dec. to
Jan
Feb. to
Mar.
April to
May
June to
July
Literature Survey
LA-SPIF set up and
Experimentation
High Speed SPIF set up, Experimental and
CAE simulation
(M.Tech guidance, Practical and UG.
Subjects)
Statistical Analysis with new Process parametric study
(M.Tech. PhD guidance, Practical and UG. Subjects)
Numerical study of Multi stage SPIF forming and CAE simulation
PhD work preparation and Future scope declaration

16. Tuesday, April 5, 2022 16
References
[1]Cerro, I.; Maidagan, E.; Arana,J. Rivero, A.; Rodríguez, P. P. Theoretical and experimental analysis of the dieless incremental sheet forming process. Journal of Materials
Processing Technology 2006, 177(1–3):404–408.
[2]Ambrogio, G.; Filice, L.; Micari, F. A. force measuring based strategy for failure prevention in incremental forming. Journal of Materials Processing Technology, 2006
177(1–3): 413–416.
[3]Raju, C.; Narayanan, C. S. FLD and Fractography Analysis of Multiple Sheet Single Point Incremental Forming. Transection of Indian Institute of Metals 2015. DOI
10.1007/s12666-015-0679-5
[4]Durante, M.; Formisano, A.; Langella, A.; Minutolo F. M. C. The influence of tool rotation on an incremental forming process . Journal of Materials Processing
Technology 2009, 209(9): 4621–4626.
[5]Ambrogio, G.; Filice, L.; Gagliardi, F.; Micari, F. Sheet Thinning Prediction in Single Point Incremental Forming. Advanced materials research 2005, 6-8: (479–486).
[6]Azevedo, N. G.; Farias, J. S.; Bastos, R. P.; Teixeira, P.; Davim, J.P., Alves de Sousa, R.J. Lubrication aspects during Single Point Incremental Forming for steel and
aluminum materials. International Journal of Precision Engineering and Manufacturing 2015, 16(3): 589–595.
[7]Bhattacharya, A.; Maneesh, K.; Reddy, N. V.; Cao, J. Formability and Surface Finish Studies in Single Point Incremental Forming . Journal of Manufacturing Science and
Engineering 2011, 133(6).
[8]Mirnia, M. J.; Dariani, B. M; Vanhove, H.; Duflou. J. R. Thickness improvement in single point incremental forming deduced by sequential limit analysis. International
Journal of Advanced Manufacturing Technology 2014, 70(9–12): 2029–2041.
[9]Gulati, V.; Aryal, A.; Katyal, P.; Goswami, A. Process Parameters Optimization in Single Point Incremental Forming. Journal of The Institution of Engineers (India): Series
C 2015, 97(2): 221–229.

17. Tuesday, April 5, 2022 17
[10]Taylor, P.; Echrif, S.B.M.; Hrairi, M. Significant Parameters for the Surface Roughness in Incremental Forming Process. Materials and
Manufacturing Processes 2014, 29: 697-703.
[11]Ambrogio, G.; Gagliardi, F.; Bruschi, S.; Filice, L. On the high-speed Single Point Incremental Forming of titanium alloys. CIRP Annals
- Manufacturing Technology 2013, 62(1): 243–246.
[12] Li, Y.; Liu, Z.; Daniel, W.J.T.; Meehan, P.A. Simulation and Experimental Observations of Effect of Different Contact Interfaces on the
Incremental Sheet Forming Process. Materials and Manufacturing Processes 2014, 29:121–128.
[13]Cristino, V. A. M; Silva, M. B.; Martins, P. A. F. Hole-flanging of metals and polymers produced by single point incremental forming.
International Journal of Materials and Product Technology 2015, 50(1) 37-48.
[14]Fan, G.; Gao, L. Numerical simulation and experimental investigation to improve the dimensional accuracy in electric hot incremental
forming of Ti-6Al-4V titanium sheet. International Journal of Advanced Manufacturing Technology 2014, 72(5–8): 1133–1141.
[15]Golabi, S.; Khazaali, H. Determining frustum depth of 304 stainless steel plates with various diameters and thicknesses by incremental
forming. Journal of Mechanical Science and Technology 2014, 28(8): 3273–3278.
[16] Ghamdi, K.A.; Hussain, G.; Butt, S.I. Force Variations with Defects and a Force-based Strategy to Control Defects in SPIF. Materials
and Manufacturing Processes 2014, 29:1197-1204.
[17]Azaouzi, M.; Lebaal, N. Tool path optimization for single point incremental sheet forming using response surface method. Simulation
Modelling Practice and Theory 2012, 24:49–58.

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