Rapid Manufacturing

at the service of a special industry at the service of a special industry

Index
Description of the ISF technology
Part examples
FLEXFORM
Consortium Consortium
Projects summary
Highlights
2
Description of the technology
Dieless Asymmetric Incremental Sheet Forming Dieless Asymmetric Incremental Sheet Forming
(AISF) is a sheet metal forming technology allowing
for the easy and rapid manufacture of sheet metal
parts of complicated profile, with the advantage of p p p , g
requiring none or greatly reduced tooling efforts
compared to traditional processes compared to traditional processes.
3
Description of the technology
Based on:
- incremental deformation technique
The part is formed as a result of small deformations applied The part is formed as a result of small deformations applied
successively in localised areas of the sheet.
- rapid manufacturing technologies
The part can be formed directly froma 3D CADmodel
The part is manufactured by layers The part is manufactured by layers
4
Description of the technology
Conventional drawing process:
Th t i l fl ithi th di i i th d i d h The material flows within the die, acquiring the desired shape.
There is no important thickness variation
Incremental Sheet Forming:
Submitted to localized pressure, the material can only deformby
decreasing its thickness locally decreasing its thickness locally.
This imposes a limitation on the maximum angle that can be
formed in one step: large angles will produce excessive thinning
in the sheet metal blank =>solved by multi-stage forming
5
in the sheet metal blank >solved by multi stage forming
Description of the technology
6
Description of the technology
Dieless
Using a partial
die
Using a dedicated die
No tooling Higher accuracy
Characte-
ristics
No tooling
required
Very high flexibility
Reduced
Intermediate
Good
compromise
Higher accuracy
Enables complex
geometries
Good flexibility Reduced
accuracy /
simple parts
compromise Good flexibility
Needs moveable
blank holder
Full
die
Blank
holder
Sheet
Partial
die
Set-up
F i
Support
7
Forming
head
Support
rig
Description of the technology
DLNC-PC Dieless forming machine of ASCAMM
Max forming size: 2000x1300x500 mm
Max blank size: 2100x1450 mm
F i it ( t i l t l) 0 5 3 Forming capacity (stainless steel): 0,5~3 mm
Forming capacity (aluminium): 0 5~4 0 mm Forming capacity (aluminium): 0,5 4,0 mm
8
Part examples
1mm steel; Aprox. Dim.: 150*150*100mm
1mm aluminium
A Di 600*400*5
1.5mm steel; Aprox. Dim.: 150*90*50mm
Aprox. Dim.: 600*400*5mm
9
1mm aluminium; Aprox. Dim.: diam 80*70mm
Title: Development of a flexible manufacturing process for the low
series production of metal parts for customand special vehicles series production of metal parts for customand special vehicles
Collective Research of the VI
th
FP
Coordinator: ASERM Coordinator: ASERM
10
Consortium
IAG:
SMEs:
- ASERM (Spain)
- SERNAUTO (Spain)
- Planchisteria Bergadana SL (Spain)
- ECOROLL (Germany)
RTD:
- ASCAMM (Spain)
SERNAUTO (Spain)
- GTMA (UK)
( y)
- LANDRA (Italy)
- ASCAMM (Spain)
- RWTH-IBF (Germany)
- FOSTA (Germany)
TECOS (Slovenia)
- Edaetech (Portugal)
Quantech (Spain)
- CIMNE (Spain)
S C ( )
- TECOS (Slovenia)
- AIMME (Spain)
- Quantech (Spain)
- Formtech (Germany)
- INSIC (France)
- CETIM (France)
- Puigjaner (Spain)
- Drescher (Germany)
11
Projects summary
Pooling the competence and experience of 19 participants, from 6 EU
countries countries
Solution for the future of special vehicle manufacturers and in g
al
for short
batches of sheet metal parts
Objectives of the project j p j
Adaptation of AISF technology for industrial application
Development of a specific CAE software for computer aided process design
Technological transfer towards the industrial sectors Technological transfer towards the industrial sectors
12
Highlights WP1
Analysis of basic properties of parts manufactured by ISF, and
benchmark against the same parts made by other technologies benchmark against the same parts made by other technologies.
Example of thickness comparison (for a cylindrical cup manufactured
by ISF and deep drawing.)
Fi 1 B h k t d thi k i (IBF) Figure 1: Benchmark part and thickness comparison (IBF)
13
Highlights WP1
New incremental sheet forming strategies
Springback: depends on geometry, sheet material and tool trajectory. Specific
multistage strategies were developed and as general conclusion, multi-stage
strategies can be used to increase the geometrical accuracy.
Main reason: the interaction of forming and strain hardening.
Vorform preform
preform

Strategy 1
final form
Endform
final form
Vorform preform
Strategy 2
final form
E df
Strategy 3
Figure 2: comparison of strategies for springback reduction (IBF)
Endform
final form
Strategy 3
14
Highlights WP1
In a second case of multi-stage strategy development, a modified
Kitazawas strategy has been developed successfully by IBF to Kitazawa s strategy has been developed successfully by IBF to
form a cylindrical cup with vertical walls and improved thickness
di t ib ti distribution
die
tool
die
tool tool
metal sheet metal sheet metal sheet metal sheet
after pre-form
D
metal sheet
after pre-form
metal sheet
after pre-form
D

D
=Draw angle

W
=Wall angle

D
=Draw angle

W
=Wall angle

D
=Draw angle

W
=Wall angle

W
15
Highlights WP2
The development of an application for knowledge management of
ISF processes This application has been developed under the free ISF processes. This application has been developed under the free
software Velneo
Figure 3: Knowledge management application interface (ASCAMM)
16
Highlights WP2
Development of advanced forming:
Modification of burnishing tools from Ecoroll
Development of non metallic tools to be used with sheet materials Development of non metallic tools to be used with sheet materials
presenting abrasive wear with hard steel
Investigation of non conventional tools to reduce springback
Figure 4: Modified burnishing tool from Ecoroll used for ISF g g
17
Highlights WP2
New process steps have being investigated with the objective to improve the global
process: improve parts quality, reduced spring-back, incorporate finishing operation: process: improve parts quality, reduced spring back, incorporate finishing operation:
- Bending operations
- Heat treatments
- Automated and integrated polishing operations Automated and integrated polishing operations
Figure 5 & 6: heat treated part deviation map and polishing process (Ascamm)
18
Highlights WP2
The development of a specific simulation software combining
incremental and simplified approach is ongoing incremental and simplified approach is ongoing
Figure 7: software interface and results display (CIMNE & Quantech)
19
Highlights WP3
Definition of industrial benchmark parts: the three industrial
benchmarks presented hereafter have been selected by benchmarks presented hereafter have been selected by
FLEXFORMs SMEs:
Figure 8: Industrial benchmark parts selected
Aluminium 1mm
(Landra, Drescher and Planchisteria Bergadana)
Aluminium 1mm
Dimensions aprox.:
600*400*5mm
20
Highlights WP3
Manufacture of industrial benchmark: Landras part
21
Highlights WP3
A study has been realized on how to modify and adapt a milling
machine to perform ISF. This modification is being implemented at machine to perform ISF. This modification is being implemented at
Edaetech
Figure 9: Adapted sheet support
22
Thank you for your attention! Thank you for your attention!
Benjamin CAVALLINI Benjamin CAVALLINI
Materials and Manufacturing dpt.
Ascamm Technology Centre
e-mail: bcavallini@ascamm.com @
Tel.: +34 93 594 47 00
23