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Influence of Tool Diameter in Single Point Incremental Forming of Polymeric Materials

Single point incremental forming (SPIF) is a versatile and cost-effective manufacturing process used extensively in prototyping and low-batch engineering components. It involves the precise movement of a tool over a thin sheet of material, incrementally deforming it into the desired shape. Process parameters significantly influence the quality and formability of the formed component. Factors such as spindle speed, feed rate, toolpath geometry, and tool dimensions impact material deformation, surface finish, and dimensional accuracy. Optimal parameter selection is critical to avoid defects like springback, wrinkling, tearing, or excessive surface degradation, particularly in polymers. Adjusting these parameters enables SPIF to accommodate a wide range of materials and geometries, making it a versatile manufacturing solution for various industries.

The work presented herein investigates the effect of process parameters, namely tool diameter and step size on the formability of polymeric materials. The materials investigated in this study are polycarbonate and nylon 6. A full factorial design of experiments schedule was conducted. Tool diameters varied between 8 mm and 20 mm and step sizes varied between 0.5 mm and 2.0 mm. Feed rate and wall angle remained constant. throughout the experiments. Various measurements took place, such as profile evaluation, thickness distribution, and surface roughness. It was found that in most cases, small tool diameters result in better formability, minimum springback, and more uniform thinning. Additionally, no discernable trend was observed between forming conditions and surface roughness.

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Work Title Influence of Tool Diameter in Single Point Incremental Forming of Polymeric Materials
Access
Open Access
Creators
  1. Rachel Diefenderfer
  2. Chad Vanderwiel
  3. Ihab Ragai
  4. Mark Rubeo
  5. Natalie Barkley
  6. Conner Best
  7. Kristofer Laser
Keyword
  1. Incremental forming
  2. Polymers
  3. Process parameters
  4. Sheet forming
License In Copyright (Rights Reserved)
Work Type Article
Publisher
  1. Proceedings of the ASME International Mechanical Engineering Congress & Exposition. Volume 2: Advanced Manufacturing
Publication Date January 23, 2025
Publisher Identifier (DOI)
  1. https://doi.org/10.1115/IMECE2024-145610
Deposited February 17, 2025

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Version 1
published

  • Created

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added 2024_Diefenderfer_et_al_2024.pdf

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator Rachel Diefenderfer

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator Chad Vanderwiel

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator Ihab Ragai

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator M Rubeo

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator Natalie Barkley

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator Conner Best

    February 17, 2025 11:30 by Researcher Metadata Database

  • Added Creator Kristofer Laser

    February 17, 2025 11:30 by Researcher Metadata Database

  • Published

    February 17, 2025 11:30 by Researcher Metadata Database

  • Updated

    February 17, 2025 21:04 by [unknown user]

  • Updated Keyword, Publisher, Description Show Changes

    April 09, 2025 14:16 by avs5190

    Keyword
    • Incremental forming, Polymers, Process parameters, Sheet forming
    Publisher
    • Proceedings of the ASME International Mechanical Engineering Congress & Exposition
    • Proceedings of the ASME International Mechanical Engineering Congress & Exposition. Volume 2: Advanced Manufacturing
    Description
    • No
    • Single point incremental forming (SPIF) is a versatile and cost-effective manufacturing process used extensively in prototyping and low-batch engineering components. It involves the precise movement of a tool over a thin sheet of material, incrementally deforming it into the desired shape. Process parameters significantly influence the quality and formability of the formed component. Factors such as spindle speed, feed rate, toolpath geometry, and tool dimensions impact material deformation, surface finish, and dimensional accuracy. Optimal parameter selection is critical to avoid defects like springback, wrinkling, tearing, or excessive surface degradation, particularly in polymers. Adjusting these parameters enables SPIF to accommodate a wide range of materials and geometries, making it a versatile manufacturing solution for various industries.
    • The work presented herein investigates the effect of process parameters, namely tool diameter and step size on the formability of polymeric materials. The materials investigated in this study are polycarbonate and nylon 6. A full factorial design of experiments schedule was conducted. Tool diameters varied between 8 mm and 20 mm and step sizes varied between 0.5 mm and 2.0 mm. Feed rate and wall angle remained constant. throughout the experiments. Various measurements took place, such as profile evaluation, thickness distribution, and surface roughness. It was found that in most cases, small tool diameters result in better formability, minimum springback, and more uniform thinning. Additionally, no discernable trend was observed between forming conditions and surface roughness.
  • Renamed Creator Mark Rubeo Show Changes

    April 09, 2025 14:17 by avs5190

    • M Rubeo
    • Mark Rubeo