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Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming

1
Advanced Manufacturing Area, Tecnalia Research & Innovation, Paseo Mikeletegi 7-Parque Tecnológico, E-20009 Donostia-San Sebastian, Spain
2
Department of Mechanical Engineering, University of the Basque Country, 48013 Bilbao, Spain
*
Author to whom correspondence should be addressed.
Metals 2019, 9(6), 697; https://doi.org/10.3390/met9060697
Received: 23 May 2019 / Revised: 12 June 2019 / Accepted: 18 June 2019 / Published: 20 June 2019
(This article belongs to the Special Issue New Processes and Machine Tools for Advanced Metal Alloys)
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Abstract

The present work focuses on the manufacturing of Ti-6Al-4V parts using hot single point incremental forming (SPIF), a non-conventional forming technology mainly oriented toward the fabrication of prototypes, spare parts, or very low volume series. In the used procedure, the entire sheet is heated and kept at uniform temperature while the tool incrementally forms the part, with the limited accuracy of the obtained parts being the major drawback of the process. Thus, this work proposes two approaches to improve the geometric accuracy of Ti-6Al-4V SPIF parts: (i) correct the tool path by applying an intelligent process model (IPM) that counteracts deviations associated with the springback, and (ii) skip overforming deviations associated with the deflection of the sheet along the perimeter of the part based on a design improvement. For this purpose, a generic asymmetric design that incorporates features of a typical aerospace Ti-6Al-4V part is used. The results point out the potential of both solutions to significantly improve the accuracy of the parts. The application of the IPM model leads to an accuracy improvement up to 49%, whereas a 25.4% improvement can be attributed to the addendum introduction. The geometric accuracy study includes the two finishing operations needed to obtain the part, namely decontamination and trimming. View Full-Text
Keywords: Ti-6Al-4V; incremental sheet forming; hot forming; geometric accuracy Ti-6Al-4V; incremental sheet forming; hot forming; geometric accuracy
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).
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Ortiz, M.; Penalva, M.; Iriondo, E.; López de Lacalle, L.N. Accuracy and Surface Quality Improvements in the Manufacturing of Ti-6Al-4V Parts Using Hot Single Point Incremental Forming. Metals 2019, 9, 697.

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