Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming
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Incremental sheet forming
The present work focuses on the manufacturing of Ti-6Al-4V parts using hot single point incremental forming (SPIF), a non-conventional forming technology mainly oriented toward the fabrication of prototypes, spare parts, or very low volume series. In the used procedure, the entire sheet is heated and kept at uniform temperature while the tool incrementally forms the part, with the limited accuracy of the obtained parts being the major drawback of the process. Thus, this work proposes two approaches to improve the geometric accuracy of Ti-6Al-4V SPIF parts: (i) correct the tool path by applying an intelligent process model (IPM) that counteracts deviations associated with the springback, and (ii) skip overforming deviations associated with the deflection of the sheet along the perimeter of the part based on a design improvement. For this purpose, a generic asymmetric design that incorporates features of a typical aerospace Ti-6Al-4V part is used. The results point out the potential of ...