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Title: Rapid Freeform Sheet Metal Forming: Technology Development and System Verification

Abstract

The objective of this project is to develop a transformational RApid Freeform sheet metal Forming Technology (RAFFT) in an industrial environment, which has the potential to increase manufacturing energy efficiency up to ten times, at a fraction of the cost of conventional technologies. The RAFFT technology is a flexible and energy-efficient process that eliminates the need for having geometry-specific forming dies. The innovation lies in the idea of using the energy resource at the local deformation area which provides greater formability, process control, and process flexibility relative to traditional methods. Double-Sided Incremental Forming (DSIF), the core technology in RAFFT, is a new concept for sheet metal forming. A blank sheet is clamped around its periphery and gradually deformed into a complex 3D freeform part by two strategically aligned stylus-type tools that follow a pre-described toolpath. The two tools, one on each side of the blank, can form a part with sharp features for both concave and convex shapes. Since deformation happens locally, the forming force at any instant is significantly decreased when compared to traditional methods. The key advantages of DSIF are its high process flexibility, high energy-efficiency, low capital investment, and the elimination of the need for massive amountsmore » of die casting and machining. Additionally, the enhanced formability and process flexibility of DSIF can open up design spaces and result in greater weight savings.« less

Authors:
 [1];  [2];  [3];  [4]
  1. Ford Scientific Research Lab., Dearborn, MI (United States)
  2. Boeing Research and Technology (BR&T), Seattle, WA (United States)
  3. Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States)
  4. Pennsylvania State Univ., University Park, PA (United States)
Publication Date:
Research Org.:
Ford Motor Company, Dearborn, MI (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
OSTI Identifier:
1433826
Report Number(s):
DOE-FORD-05764-1
DOE Contract Number:  
EE0005764
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 36 MATERIALS SCIENCE; energy resource at the local deformation area; greater formability; process control; process flexibility relative to traditional methods; double-sided incremental forming

Citation Formats

Kiridena, Vijitha, Verma, Ravi, Gutowski, Timothy, and Roth, John. Rapid Freeform Sheet Metal Forming: Technology Development and System Verification. United States: N. p., 2018. Web. doi:10.2172/1433826.
Kiridena, Vijitha, Verma, Ravi, Gutowski, Timothy, & Roth, John. Rapid Freeform Sheet Metal Forming: Technology Development and System Verification. United States. doi:10.2172/1433826.
Kiridena, Vijitha, Verma, Ravi, Gutowski, Timothy, and Roth, John. Sat . "Rapid Freeform Sheet Metal Forming: Technology Development and System Verification". United States. doi:10.2172/1433826. https://www.osti.gov/servlets/purl/1433826.
@article{osti_1433826,
title = {Rapid Freeform Sheet Metal Forming: Technology Development and System Verification},
author = {Kiridena, Vijitha and Verma, Ravi and Gutowski, Timothy and Roth, John},
abstractNote = {The objective of this project is to develop a transformational RApid Freeform sheet metal Forming Technology (RAFFT) in an industrial environment, which has the potential to increase manufacturing energy efficiency up to ten times, at a fraction of the cost of conventional technologies. The RAFFT technology is a flexible and energy-efficient process that eliminates the need for having geometry-specific forming dies. The innovation lies in the idea of using the energy resource at the local deformation area which provides greater formability, process control, and process flexibility relative to traditional methods. Double-Sided Incremental Forming (DSIF), the core technology in RAFFT, is a new concept for sheet metal forming. A blank sheet is clamped around its periphery and gradually deformed into a complex 3D freeform part by two strategically aligned stylus-type tools that follow a pre-described toolpath. The two tools, one on each side of the blank, can form a part with sharp features for both concave and convex shapes. Since deformation happens locally, the forming force at any instant is significantly decreased when compared to traditional methods. The key advantages of DSIF are its high process flexibility, high energy-efficiency, low capital investment, and the elimination of the need for massive amounts of die casting and machining. Additionally, the enhanced formability and process flexibility of DSIF can open up design spaces and result in greater weight savings.},
doi = {10.2172/1433826},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Sat Mar 31 00:00:00 EDT 2018},
month = {Sat Mar 31 00:00:00 EDT 2018}
}

Technical Report:

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