1. 9. Dieless Incremental Sheet Forming
Presenter: Prof. Jian Cao
Project PIs:
Jian Caoa, Kornel Ehmanna , Brad Kinseyb, Yannis Korkolisb
aNorthwestern University
bUniversity of New Hampshire

2. 9. Dieless Incremental Sheet Forming
Industrial Needs and Relevance:
A fast and flexible process to produce functional, prototype sheet metal parts and/or potentially repair old components
Stamping is commonly used for making sheet metal parts: costs $10K to $1M to make the dies as well as 8 ~ 25 weeks to complete.
Describe the importance of the research on the Center’s industrial members (i.e., the concern currently experienced by industry or the opportunity which will be enabled through the research project). Also if relevant, mention other competing available technologies and why this proposed approach is better or different. (On each slide, please include pictures or figures to assure the presentation is more engaging.)
Incremental Sheet Forming (ISF) utilizes simple tooling (< $500). ISF also reduces the time from CAD-to-final-part (< 1 week).
NSF I/UCRC Planning Meeting

3. 9. Dieless Incremental Sheet Forming
Example Parts Made by Incremental Sheet Forming:
NSF I/UCRC Planning Meeting

4. 9. Dieless Incremental Sheet Forming
Project Objectives:
An analytical thickness prediction model that can account for different toolpath strategies
Max Error Goal: ±5 %
Predict the location of fracture
Max Error Goal: ±2 mm
Maintain satisfactory geometric accuracy
Max Error Goal: ±1 mm
Gen. 1 DSIF Machine at NU
What will be accomplished through the research project and implemented as an outcome work. Ideally, there will be multiple objectives.
No Fracture
NSF I/UCRC Planning Meeting

5. 9. Dieless Incremental Sheet Forming
Approach/Methodologies:
Material characterization and state-of-the-art plasticity models using the UNH’s facilities
Simulate ISF (FEA) and validate through-the-thickness mechanics via experiments
Propose a fast, semi-analytical model to predict thickness based on learnt mechanics
Finite Element Simulation of DSIF
Provide the specific tasks that will be completed as part of the project, facilities utilized, and lead researchers.
NSF I/UCRC Planning Meeting

6. 9. Dieless Incremental Sheet Forming
Fracture
Baseline
Deliverables:
Best-choice process parameters for DSIF to improve geometric accuracy and prevent excessive thinning
Fast, semi-analytical model to predict sheet thickness after forming
Novel validation techniques to test today’s comprehensive plasticity and fracture models
Numerical simulation model of DSIF
Compensated
List critical items that will be provided to the Center’s industrial members as a result of this research (both after the first year and end of the project). These could include technical reports, knowledge, software, hardware, etc.
NSF I/UCRC Planning Meeting

7. 9. Dieless Incremental Sheet Forming
Budget and Timeline:
Estimated cost of project is $450k for three years.
Task / Milestone
Year 1
Year 2
Year 3 Q1 Q2 Q3 Q4
Material Characterization
DSIF Simulation Model
Thickness Prediction Model
Geometric Accuracy Control
Fracture Prediction
Desired Process Control Goals
Provide these critical items for the research project, including specifying the personnel involved.
NSF I/UCRC Planning Meeting

8. 9. Dieless Incremental Sheet Forming
Discussion:
Are the industrial need and relevance accurately captured?
Are the objectives realistic and complete?
Are the approaches technically sound and appropriate?
Are there alternative implementation paths or better approaches?
Are the deliverables impactful to industrial partners?
Are the budget and timeline reasonable?
Are there conflicts with intellectual property or trade secrets?
NSF I/UCRC Planning Meeting

9. 9. Dieless Incremental Sheet Forming
Back Up Slides
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10. 9. Dieless Incremental Sheet Forming
Desktop
Describe the importance of the research on the Center’s industrial members (i.e., the concern currently experienced by industry or the opportunity which will be enabled through the research project). Also if relevant, mention other competing available technologies and why this proposed approach is better or different. (On each slide, please include pictures or figures to assure the presentation is more engaging.)
Gen-1
Gen-2
NSF I/UCRC Planning Meeting