A numerical approach to optimize the toolpath strategy for polymers forming

A numerical approach to optimize the toolpath strategy for polymers forming

FORMISANO Antonio, DURANTE Massimo, BOCCARUSSO Luca, MEMOLA CAPECE Fabrizio

Abstract. Incremental sheet forming is a relatively new technology with a deformation strategy that resembles the layered manufacturing principle of rapid prototyping; thanks to this, it can represent a viable way to form metal and polymer sheets, guaranteeing high customization and cost-effectiveness. On the other hand, and particularly when considering thermoplastic sheets, the components obtained by this process suffer from peculiar defects like, for example, twisting and wrinkling. A way of reducing the risk of such defects is to optimize the toolpath strategy to lower in-plane forming forces. To pursue this aim, the present work follows a numerical approach; a commercial FE code was used to simulate the incremental forming of polycarbonate sheets by varying the toolpath strategy. The investigation of some features like the forming forces and the deformation states was carried out, with the goal of determining an optimized toolpath strategy for the reduction of the incremental forming forces and the consequent expectation of reduced risk of failures and defects for incremental formed polymer sheets.

Keywords
Incremental Sheet Forming, Polymers, FE Analysis, Toolpath Strategy

Published online 4/19/2023, 6 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: FORMISANO Antonio, DURANTE Massimo, BOCCARUSSO Luca, MEMOLA CAPECE Fabrizio, A numerical approach to optimize the toolpath strategy for polymers forming, Materials Research Proceedings, Vol. 28, pp 1697-1702, 2023

DOI: https://doi.org/10.21741/9781644902479-183

The article was published as article 183 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] M. Hassan, G. Hussain, H. Wei, A. Qadeer, M. Alkahtani, Progress on Single-Point Incremental Forming of Polymers, Int. J. Adv. Manuf. Technol. 114 (2021) 1-26. https://doi.org/10.1007/S00170-021-06620-7
[2] G. Centeno, I. Bagudanch, D. Morales-Palma, M.L. García-Romeu, B. Gonzalez-Perez-Somarriba, A.J. Martinez-Donaire, L.M. Gonzalez-Perez, C. Vallellano, Recent Approaches for the Manufacturing of Polymeric Cranial Prostheses by Incremental Sheet Forming, Procedia Eng. 183 (2017) 180-187. https://doi.org/10.1016/J.PROENG.2017.04.059
[3] A. Formisano, L. Boccarusso, F. Capece Minutolo, L. Carrino, M Durante, A. Langella, Negative and Positive Incremental Forming: Comparison by Geometrical, Experimental and FEM Considerations, Mater. Manuf. Process. 32 (2017) 530-536. https://doi.org/10.1080/10426914.2016.1232810
[4] M. Durante, A. Formisano, F. Lambiase, Incremental Forming of Polycarbonate Sheets, J. Mater. Process. Technol. 253 (2018) 57-63. https://doi.org/10.1016/j.jmatprotec.2017.11.005
[5] M. Durante, A. Formisano, F. Lambiase, Formability of Polycarbonate Sheets in Single-Point Incremental Forming, Int. J. Adv. Manuf. Technol. 102 (2019) 2049-2062. https://doi.org/10.1007/s00170-019-03298-w
[6] A. Formisano, M. Durante, A Numerical-Experimental Investigation on the Wrinkling Defect in Incremental Forming of Thin Polycarbonate Sheets, Int. Rev. Model. Simul. 12 (2019) 206-211. https://doi.org/10.15866/iremos.v12i4.17614
[7] N. Rosca, T. Trzepieciński, V. Oleksik, Minimizing the Forces in the Single Point Incremental Forming Process of Polymeric Materials Using Taguchi Design of Experiments and Analysis of Variance, Materials 15 (2022) 6453. https://doi.org/10.3390/ma15186453
[8] H. Wei, L. Zhou, B. Heidarshenas, I.K. Ashraf, C. Han, Investigation on the Influence of Springback on Precision of Symmetric-Cone-Like Parts in Sheet Metal Incremental Forming Process, Int. J. Light. Mater. Manuf. 2 (2019) 140-145. https://doi.org/10.1016/j.ijlmm.2019.05.002
[9] Z. Chang, J. Chen, Mechanism of the Twisting in Incremental Sheet Forming Process, J. Mater. Process. Technol. 276 (2020) 116396. https://doi.org/10.1016/j.jmatprotec.2019.116396
[10] J.R. Duflou, H. Vanhove, J. Verbert, J. Gu, I. Vasilakos, P. Eyckens, Twist Revisited: Twist Phenomena in Single Point Incremental Forming, CIRP Ann. Manuf. Technol. 59 (2010) 307-310. https://doi.org/10.1016/j.cirp.2010.03.018