Key Engineering Materials Submitted: 2014-09-11

ISSN: 1662-9795, Vols. 656-657, pp 479-483 Accepted: 2014-11-10

doi:10.4028/www.scientific.net/KEM.656-657.479 Online: 2015-07-23
© 2015 Trans Tech Publications Ltd, Switzerland

RECOMMENDATION OF A MEASURE FOR ENHANCING THE

PRECISION OF DIMENSIONS OF FOIL PRODUCTS IN SINGLE POINT
INCREMENTAL FORMING TECHNOLOGY
Le Khanh Dien1,a*, Nguyen Tan Hung2,b, Nguyen Thien Binh2,c,
Le Thanh Son2,d, Nguyen Huy Bich3,e, Nguyen Thanh Nam2,f
1
University of Technology, Vietnam National University Ho Chi Minh City, 268 Ly Thuong Kiet,
Dictrict 10, Ho Chi Minh, Vietnam
2
National Key Lab of Digital Control and System Engineering, University of Technology, Vietnam
National University Ho Chi Minh City, 268 Ly Thuong Kiet, Dictrict 10, Ho Chi Minh, Vietnam
3
Nong Lam University, Linh Trung Ward, Thu Duc Dictrict, Ho Chi Minh, Vietnam
a
lkdien@hcmut.edu.vn , btanhung@dcselab.edu.vn, cthienbinh@dcselab.edu.vn
d
thanhson@dcselab.edu.vn, enhbich@hcmuaf.edu.vn , fthanhnam@dcselab.edu.vn

Keywords: Single Point incremental Forming (SPIF), Plasticity deforming, Precision of

dimensions, Springback, Elasto-plastic materials

Abstract: Single Point Incremental Forming (SPIF) has become a popular technology of
forming sheet materials in the recent decades. However, the springback phenomenon, an inborn
property of almost all elasto-plastic materials, reduces the precision of dimensions of the products
by the finished forming session. This paper attempts to find out a measure to minimize this
unwanted obstacle by using both empirical and simulating methods in order to define the relations
of springback values among the forming parameters such as diameter of the forming tool, its
revolution per minute, its velocity and its feed rate. Analyzing these equations to extract the
appropriate parameters of forming for enhancing the precision of SPIF products is the final aim of
this paper.

1. Introduction
Single Point Incremental Forming(SPIF ) and Two Point Incremental Forming(TPIF) are two
methods of Incremental Sheet Forming technology(ISF), a new dieless forming sheet technology
that was recommended by E. Leszak in 1967 [1]. However, this forming sheet technology could not
be applied in industry in the early years because of the weakness of the control technology of this
time. From 1997 to now on, this method has been developed rapidly and has definitive great results
in industry in advanced countries... Unfortunately elasto-plastic is an inborn property of almost all
materials that engenders unwanted springback phenomenon [2], [3] and reduces the accuracy of the
dimensions and of the shapes of the products. The scheme of this paper is to apply both empirical
and simulation methods to gather the average springback values of depth dimensions of the result
models in form of regression equations that are examined to minimize the effect of springback
value in SPIF technology.

2. Initial Selections For Simulation Method And Empirical Method

In order to easily compare the result of 2 processes, these following selections have applied for 2
processes of studying:
- Material of model: aluminum A 1050 H14, mild steel B420, stainless steel SS 304 and PVC
[4] are selected for the material of the model.
- Shape of model: a designed circular lateral shape model with R=60, L=250, the height h is
depended on the capacity of deformation of the material, ideal value is equal to R as in figure 1.

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480 Recent Development in Machining, Materials and Mechanical Technologies

Figure 1: Model of SPIF in simulation and in empirical practice.

- Tools: a set of HSS spherical tip tool is used (figure 9b)
- A set of forming parameters in simulation process as well as in empirical process:
Vz (mm): vertical feed rate after a contour,
Vxy (mm/minute) velocity of tool on the orbit contour,
D (mm): diameter of spherical tip of the tool,
n (RPM): the revolution per minute of the tool for forming metal materials sheet by SPIF
technology. With PVC material, this parameter is replace by the forming temperature T(0C)
because the temperature has more effect in deformation of PVC when forming. This article will
study and analyze the influences of 4 above parameters to the springback of the materials. We use
Partial Linear Planning for these 4 parameters (n or T is selected as replaceable parameters), each
parameter has 2 limited values. So the number of models is 24-1=8 in simulation as well as in
practical process. The selected values of these parameters for 8 models by empirical and simulating
process are shown in table 2.

Simulation Process Of Spif For Determine The Value Of Springback

The simulation process of SPIF could be displayed in the following steps:
a. Design the orbit of the spherical tip tool by using the same G-code file of CAD-CAM
software of the orbit of model in empirical process with a small exchange to suitable format
of FEM simulation software.
b. Define time and coordinate amplitude of the reference point of tool
c. Selection of element type for FEM software

Element S4R (Shell 4 knots Reduce) in table 2 is selected because of its conformity [5]
d. Making parts: sheet and tool, assembly and defining boundary conditions

Figure 2: Design sheet, tool, assembly and defining boudary conditions. Materials of model sheet
and tool are selected also in this section.
e. Meshing (S4R), simulating, select diagonal line of measure section and forming diagram of
dimentions in the section of the result model
f. Each set of value of parameters of table in figure 2 is performed for simulation and draw
the dimension of simulation model and the initial dimension of CAD design to determine the
 Key Engineering Materials Vols. 656-657 481

springback as in a case that is shown in the following figure. The maximum different depth
∆H of each case is recorded.

Figure 5: Comparision the dimension of simulation model and the initial dimension of CAD
design in a case of 4 materials. In observing these diagram we concluse that the maximum depth
pringback is important and easy to measure in accuracy so we study the springback of this direction.

3. Empirical Process of Spif for Determine the Value of Springback

The simulation process of SPIF could be displayed in the following steps:
a. Design the orbit of the spherical tip tool (Fig 1) by using the G-code file of CAD-CAM
software, the one that is used for Simulation process with a suitable converting.
b. Select SPIF machine and tool for forming models

Figure 6: SPIF machine and spherical tip tools are used in empirical processes in DCSELAB, the
Ho Chi Minh University of Technology, Vietnam. The depth z is also one coordinate of tool tip
(reference point)
c. Because of the unwanted contigent influences in empirical process we have to perform 3
models and get the average maximum depth and compare with the z coordinate of tool in G-
code for the most accuracy springback.

4. Performance the Average Value of 2 Methods

The results of depth springback values by 2 methods are presented in table 1 included the
average values ∆HAvg. They are naturally different because the simulation method depends on the
software, the setting of properties of materials… in the meanwhile the results of empirical method
depend on so many real influence of hazard parameters of manufacturing, environment…
482 Recent Development in Machining, Materials and Mechanical Technologies

Table 1: The result of the depth springback by simulation ∆HSi, by empirical method ∆HEm and
average value ∆HAvg.

A1050-H14 SS 304

Vz D Vxy n ∆HSi ∆HEm ∆HAvg Vz D Vxy n ∆H Si ∆HEm ∆HAvg

0.2 5 800 400 0.623 0.656 0.6395 0.2 5 800 400 0.994 1.052 1.023
1 5 800 2500 0.463 0.511 0.487 1 5 800 800 1.05 1.13 1.09
0.2 10 800 2500 0.412 0.429 0.4205 0.2 10 800 800 0.834 0.882 0.858
1 10 800 400 0.742 0.738 0.74 1 10 800 400 0.62 0.639 0.6295
0.2 5 3000 2500 0.557 0.563 0.56 0.2 5 3000 800 1.106 1.081 1.0935
1 5 3000 400 0.451 0.416 0.4335 1 5 3000 400 0.603 0.573 0.588
0.2 10 3000 400 0.784 0.812 0.798 0.2 10 3000 400 0.746 0.793 0.7695
1 10 3000 2500 0.826 0.826 0.826 1 10 3000 800 0.552 0.562 0.557
B420 PVC

Vz D Vxy n ∆HSi ∆HEm ∆HAvg Vz D Vxy T ∆HSi ∆HEm ∆HAvg

0.2 5 800 400 0.845 0.853 0.849 0.4 6 1000 30 1.89 1.75 1.82
1 5 800 2000 0.523 0.525 0.524 1.2 6 1000 50 2.33 2.24 2.285
0.2 10 800 2000 0.321 0.312 0.3165 0.4 12 1000 50 2.71 2.52 2.615
1 10 800 400 0.49 0.428 0.459 1.2 12 1000 30 2.26 2.31 2.285
0.2 5 3000 2000 0.367 0.364 0.3655 0.4 6 2500 50 1.2 1.17 1.185
1 5 3000 400 0.364 0.336 0.35 1.2 6 2500 30 1.89 1.97 1.93
0.2 10 3000 400 0.587 0.622 0.6045 0.4 12 2500 30 1.52 1.49 1.505
1 10 3000 2000 0.724 0.757 0.7405 1.2 12 2500 50 2.24 2.47 2.355
Apply the average values of depth springback ∆HAvg into linear planning process we receive 4
regression equations of depth springback values of 4 materials with the suitable Estimated Effects
and Coefficients and eliminate the non signification coefficients we obtain 4 regression equations
for each material:
Aluminum A 1059 H 14:
∆H=0.987 + 0. 24Vz - 0.065D – 0.00048Vxy + 0.078.D.Vz +0.000027D.Vxy–0.000075. Vz .Vxy (1)
Stainless steel SS 304:
∆H =0.57+ 0.724Vz + 0.064D– 0.251Vxy+ 0.027DVz + 0.760DVxy– 0.023n (2)
Mild steel B 420: ∆H =0.011+ 0.100625 Vz – 0.000229 D +0.035625 Vz D (3)
PVC: ∆H = -0.35 + 1.719Vz + 0.098D – 0.00057Vxy + 0.04375T – 0.028Vz.D + +0.0005Vz.Vxy–
0.03625Vz.T (4)

5. Analyze The Regression Equations:

With the above regression equations we could apply the optimization analyze to have the
selected forming parameters with the objective of the minimum depth springback value and we
have some conclusions: Diameter of the tool tip could be as small as possible, in practice the
smallest could be D=3mm; the springback values of SS 304 and PVC are bigger the other materials;
velocity of tool on the orbit contour Vxy is as small as possible; the effect of the revolution per
minute is not important for 4 materials.
 Key Engineering Materials Vols. 656-657 483

6. Conclusion
With the combination of simulation and empirical method we could use the tools of planning
and optimization to increase the accuracy of shape and dimensions by selection a suitable set of
SPIF parameters forming.

7. Acknowledgement
This research was supported by National Key Laboratory of Digital Control and System
Engineering (DCSELAB), HCMUT, VNU-HCM.

REFERENCES
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10.1007/s00170-013-4870-8
[3] Jacob Lubliner, Plasticity theory., University of California at Berkerley, revised edition (PDF)
2005
[4] ASM International, Alas of stress-strain curves , 2nd Efition @2002 ASM,
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[5] Dassault Corp. , Abaqus user manual, ANALYSIS 1,2,3,4,5,5a, 2009