Critical factors, limits and applications in incremental forming

金属板成形作为一种制造技术已经存在了很多年;成形是指通过增加应力使材料塑性流动而使材料成形的变形过程。增量成形（IF）是一种更现代的工艺，其中在材料中进行小变形，特定顺序的小变形导致所需的形状。单点渐进成形（SPIF）是一种高柔性、低成本的金属板材成形新工艺。SPIF有可能对快速成型、小批量生产和定制生产产生重大影响。由于不需要特定的成型模具和使用机械车间常见的设备，该工艺具有极强的适应性。成形是通过使用通用夹具和成形工具使材料逐渐变形来实现的。随着对特定部件的需求的增加，完成了试错实验研究，以确定如何生产该部件。为了使SPIF成为钣金成形中的实用制造工艺，需要进行更多的基础研究来了解该工艺;从而消除了对单个零件进行试错研究的需要。为了提高SPIF的知识基础，进行更多的系统研究，以确定许多过程变量对SPIF的影响。目前的研究计划将包括确定关键因素的基本实验研究;如材料类型、材料厚度、机床进给速度、刀具尺寸、润滑类型等。所提出的研究建立在以前的参数研究基础上，只研究了一小部分变量。通过开展这项研究，获得了更多的渐进成形知识，这将增加应用的机会。

Sheet metal forming has existed for many years as a manufacturing technique; forming refers to the deformation process through which a material is shaped by the addition of stresses causing the material to flow plastically. Incremental forming (IF) is a more modern process where small deformations are made in the material, a specific sequence of small deformations result in the desired shape. Single Point Incremental Forming (SPIF) is a highly flexible and cost effective new sheet metal forming process for limited quantity manufacturing. SPIF has the potential to have a significant impact on rapid prototyping, low quantity production and customized production. The process is extremely adaptable due to the lack of need for part specific forming dies and the use of equipment that is commonly found in machine shops. Forming is achieved by incrementally deforming material with the use of a generic fixture and forming tools.The advancements in SPIF have occurred as required. As the need arose for specific parts, a trial-and-error experimental studies were completed to determine how to produce the part. To make SPIF a practical manufacturing process in sheet metal forming, more fundamental research is needed to understand the process; thus eliminating the need for trial-and-error studies of individual parts. To advance the knowledge base of SPIF the undertaking of more methodical studies to determine effects the many process variables have on SPIF.The present research program will include fundamental experimetnal studies to determine critical factors; such as material type, material thickness, machine feedrate, tool size, lubrication type, etc. The proposed research builds on a previous parametric study, where only a small number of the variables were investigated. By undertaking this research greater knowledge of incremental forming is achieved, this will improve the opportunites for applications.