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Title: Residual Stress In Sheet Metal Parts Made By Incremental Forming Process

Abstract

Incremental sheet metal forming, which uses a CNC forming stylus, is new flexible forming process not requiring the use of any expensive dies. We have applied the incremental forming process to dental prosthesis. This new process, however, posed difficult problems. After removing the outer portion of the incremental formed sheet metal part, the inner part is distorted. In this paper, the residual stress in the sheet metal part obtained by incremental forward stretch forming operations has been examined. Numerical simulations were conducted for solid elements. When small rigid ball slides on the metal sheet with a certain vertical feed, tension residual stress is produced in the upper layer of the sheet and compression stress in the lower. Then, the resultant moments throughout the sheet cause negative spring-back when the outer portion is removed. A systematic study of the behavior was conducted in this paper. Parameters considered included the tool radius and the vertical tool feed rate. The tip radius of forming stylus has a significant influence on the residual stress. The smaller radius of forming stylus, the larger bending force becomes. And new process with double forming styluses is examined to reduce the bending force.

Authors:
; ;  [1]; ;  [2]
  1. Faculty of Engineering, University of Shizuoka, 432-8561 Hamamatsu-shi, Shizuoka (Japan)
  2. Faculty of Dentistry, Tokyo Medical and Dental University, 113-8549 Bunkyo-ku, Tokyo (Japan)
Publication Date:
OSTI Identifier:
21061756
Resource Type:
Journal Article
Resource Relation:
Journal Name: AIP Conference Proceedings; Journal Volume: 908; Journal Issue: 1; Conference: NUMIFORM 2007: 9. international conference on numerical methods in industrial forming processes, Porto (Portugal), 17-21 Jun 2007; Other Information: DOI: 10.1063/1.2740904; (c) 2007 American Institute of Physics; Country of input: International Atomic Energy Agency (IAEA)
Country of Publication:
United States
Language:
English
Subject:
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS; ALLOYS; BENDING; COMPRESSION; COMPUTERIZED SIMULATION; LAYERS; MATERIALS WORKING; METALS; NUMERICAL ANALYSIS; RESIDUAL STRESSES; SHEETS; SOLIDS

Citation Formats

Tanaka, Shigekazu, Nakamura, Tamotsu, Hayakawa, Kunio, Nakamura, Hideo, and Motomura, Kazuo. Residual Stress In Sheet Metal Parts Made By Incremental Forming Process. United States: N. p., 2007. Web. doi:10.1063/1.2740904.
Tanaka, Shigekazu, Nakamura, Tamotsu, Hayakawa, Kunio, Nakamura, Hideo, & Motomura, Kazuo. Residual Stress In Sheet Metal Parts Made By Incremental Forming Process. United States. doi:10.1063/1.2740904.
Tanaka, Shigekazu, Nakamura, Tamotsu, Hayakawa, Kunio, Nakamura, Hideo, and Motomura, Kazuo. Thu . "Residual Stress In Sheet Metal Parts Made By Incremental Forming Process". United States. doi:10.1063/1.2740904.
@article{osti_21061756,
title = {Residual Stress In Sheet Metal Parts Made By Incremental Forming Process},
author = {Tanaka, Shigekazu and Nakamura, Tamotsu and Hayakawa, Kunio and Nakamura, Hideo and Motomura, Kazuo},
abstractNote = {Incremental sheet metal forming, which uses a CNC forming stylus, is new flexible forming process not requiring the use of any expensive dies. We have applied the incremental forming process to dental prosthesis. This new process, however, posed difficult problems. After removing the outer portion of the incremental formed sheet metal part, the inner part is distorted. In this paper, the residual stress in the sheet metal part obtained by incremental forward stretch forming operations has been examined. Numerical simulations were conducted for solid elements. When small rigid ball slides on the metal sheet with a certain vertical feed, tension residual stress is produced in the upper layer of the sheet and compression stress in the lower. Then, the resultant moments throughout the sheet cause negative spring-back when the outer portion is removed. A systematic study of the behavior was conducted in this paper. Parameters considered included the tool radius and the vertical tool feed rate. The tip radius of forming stylus has a significant influence on the residual stress. The smaller radius of forming stylus, the larger bending force becomes. And new process with double forming styluses is examined to reduce the bending force.},
doi = {10.1063/1.2740904},
journal = {AIP Conference Proceedings},
number = 1,
volume = 908,
place = {United States},
year = {Thu May 17 00:00:00 EDT 2007},
month = {Thu May 17 00:00:00 EDT 2007}
}