The Formability of Perforated TA1 Sheet in Single Point Incremental Forming

Area of Science:

• Materials Science
• Manufacturing Engineering
• Mechanical Engineering

Background:

• Single Point Incremental Forming (SPIF) is a flexible manufacturing process.
• Perforated titanium sheets present unique challenges in SPIF due to their specific material properties.
• The wall angle is a critical parameter influencing SPIF quality, especially for complex surfaces.

Purpose of the Study:

• To investigate the effect of wall angle on the SPIF of Grade 1 commercially-pure α titanium (TA1) perforated plates.
• To determine the forming limit angle and fracture mechanisms.
• To analyze the influence of wall angle on component quality, including thickness distribution and geometric accuracy.

Main Methods:

• Integration of experimental analysis and finite element modeling.
• Systematic study of varying wall angles in SPIF of TA1 perforated plates.
• Evaluation of forming limiting angle, fracture modes, and deformation mechanisms.

Main Results:

• The forming limit angle is directly related to the wall angle, with ductile fracture observed around 60 degrees.
• Thickness distribution deviates from the sine law, with actual thinning being greater.
• Increased wall angle leads to higher effective strain, thinning rate, and forming force, but reduced geometric error.

Conclusions:

• A wall angle of approximately 45 degrees yields optimal results for TA1 perforated sheets, offering uniform thickness and high geometric accuracy.
• The actual forming limit angle is lower than theoretical predictions, necessitating experimental validation.
• SPIF shows potential for manufacturing complex titanium components, with wall angle as a key control parameter.