Share
تحليل مسار العدة في عملية التشكيل التزايدية للصفائح المعدنية == Analysis of Tool Path In Incremental Sheet Metal Forming Process
Author name:
ميثم سعد علي
Supervisor name:
وسام كاظم حمدان
General topic:
Production engineering metallurgy and materials
Specific topic:
Production Engineering
Degree:
Master
University:
University of Technology
Language:
English
University location:
Baghdad
First pages:
50T168 - p.pdf
Abstract:
التشكيل التزايدي للصفائح المعدنية هو عملية مرنة للغاية ومتعددة الاستعمالات للتصنيع السريع لاجزاء الصفائح المعدنيه المعقدة حيث تمتلك امكانية التكيف بامتياز مع انظمة التحكم الرقمي بالحاسوب (مكائن التفريز المبرمج CNC) من خلال السيطرة المباشرة على بيانات CAD | Incremental sheet forming (ISMF) is a highly versatile and flexible process for rapid manufacturing of complex sheet metal parts. It has excellent adaptability to computer numerical control (CNC) systems through direct control of CAD data, minimizing the use of specialized tooling and presses. A sheet of metal is formed by a progression of localized plastic deformation using simple forming tool controlled by a CNC machine - tool. The aim of the presented thesis is to investigate the feasibility of incrementally forming of 3D complex shape (like automotive heat shield shape) and the solar cooker shape by Single Point Incremental Forming process without using a dedicated die depending on different tool paths. Six different forming tool paths (unidirectional ZLVTP, bidirectional ZLVTP, FPRTP, ZGZTP, BSLTP and HSLTP) were generated byUnigraphics - NX8 (UGS - NX8) programing system and applied to realize solar cooker shape and automotive heat shield shape. The feasibility investigation and development of automotive heat shield shape is based on three control factors are tool path type, forming tool head shape and the Z - increment (vertical pitch). For each of these factors, levels were tested. The tool head shape and vertical pitch contain their both on two levels while the tool path type on six levels. Hence, 24 experiments applied to realize automotive heat shield shape based on a full factorial design of experiments, and 6 experiments applied to realize solar cooker shape. Hybrid tool paths are tested to explore the applicability these paths in ISMF process. This thesis discussed the impact of tool paths types and other control factors (tool shape and vertical pitch) on the three different quality characteristic namely geometrical accuracy, thickness variation and forming time. The significant of the control factors are explored using two statistical methods are analysis of variance ANOVA and main effect plot. All experiments were carried out on sheets of Aluminum Alloy (AL1070) with thickness 1.5 mm by using 3axis CNC machine. The CNC machine and dial gauge are used to measure dimensional accuracy and final thickness of formed parts respectively. Depending on the results of this work, Helical - Streamline tool path (HSLTP) and follow periphery tool path (FPRTP) are achieved higher geometrical accuracy when forming the solar cooker shape and the automotive heat shield shape respectively. On the other hand, Z Level profile tool path (ZLVTP) is the best tool path to achieve homogeneous thickness distribution and minimum forming time of formed parts. Hybrid tool paths are undesirable in incremental sheet metal forming. The ANOVA results show that all control factors have influence on the accuracy, especially the tool path type. The tool shape and vertical pitch have no influence on the thickness of the formed parts. But, the vertical pitch has major effects on the forming time and accuracy. In contrast, the tool path shape has a great influence on the process implementation.
