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Article Dans Une Revue International Journal of Advanced Manufacturing Technology Année : 2024

Design and characterization of a vibrating tool for incremental sheet forming process

Résumé

In this article, the design process of a novel vibrating tool is presented to improve some key aspects of Single Point Incremental Sheet Forming (SPISF). The overall effect of a vibration assistance is an improvement of the process by decreasing certain constraints occurring duringmanufacturing (e.g., high forming forces, poor roughness and elastic springback). For developing such assistance, the objective of this study is to present the design methodology and characterization of an innovative tool. The horn-shape design of the tool is optimized to resonate at its natural frequencies in the 4–16 kHz frequency bandwidth. A frequency decoupling of the tool modes is obtained by a successful desymmetrization of the tool design to precisely control the vibration direction, focusing on axial, radial or coupled vibrating motion of the tool tip. Then, the unidirectional vibrating force generated by a piezoelectric actuator is transformed into a controlled multidirectional vibrating motion of the tool tip depending on the frequency and the amplitude of the actuator input signal. The core contribution of the paper is the design methodology itself of the forming tool, which encompasses a novel approach focused on the tool/sheet contact coupling analysis and its effect on the vibrating behavior of the tool during SPIF process conditions. All steps of the design methodology are described: from the design specifications to the prototype validation, including a finite element analysis and an experimental characterization of its modal behavior in free-end tool conditions as well as in different tool/sheet contact conditions through a simple indentation forming test inside an AA5086 metal sheet. Experimental results highlight the importance of considering process boundary conditions formodal identification and the influence of the vibration direction on the force reduction in forming conditions. A forming force reduction up to 26% is obtained exciting the 2nd bending mode of vibration of the presented forming tool identified in tool/sheet contact configuration, while reduction is less significant for the 1st and 3rd bending modes.
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jeudi 10 octobre 2024
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Dates et versions

hal-04540939 , version 1 (10-04-2024)

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Johra Marwan, Courteille Eric, Le Breton Ronan, Marie Frédéric, Levard Corentin, et al.. Design and characterization of a vibrating tool for incremental sheet forming process. International Journal of Advanced Manufacturing Technology, 2024, ⟨10.1007/s00170-024-13500-3⟩. ⟨hal-04540939⟩
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