9 Dieless Incremental Sheet Forming Presenter Prof Jian

9. Dieless Incremental Sheet Forming Presenter: Prof. Jian Cao Project PIs: Jian Caoa, Kornel Ehmanna , Brad Kinseyb, Yannis Korkolisb a. Northwestern University b. University of New Hampshire jcao@northwestern. edu

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 $10 K to $1 M to make the dies as well as 8 ~ 25 weeks to complete. • 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 Slide 2

9. Dieless Incremental Sheet Forming Example Parts Made by Incremental Sheet Forming: https: //www. youtube. com/watch? v=EBgmn. D 1 k. Pww NSF I/UCRC Planning Meeting Slide 3

9. Dieless Incremental Sheet Forming • Gen. 1 DSIF Machine at NU No Fracture NSF I/UCRC Planning Meeting Slide 4

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 throughthe-thickness mechanics via experiments • Propose a fast, semi-analytical model to predict thickness based on learnt mechanics NSF I/UCRC Planning Meeting Finite Element Simulation of DSIF Slide 5

9. Dieless Incremental Sheet Forming 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 NSF I/UCRC Planning Meeting Baseline Fracture Compensated Slide 6

9. Dieless Incremental Sheet Forming Budget and Timeline: Estimated cost of project is $450 k for three years. Year 1 Task / Milestone Q 1 Material Characterization Q 2 Year 2 Q 3 Q 4 Q 1 Q 2 Year 3 Q 4 Q 1 Q 2 Q 3 Q 4 DSIF Simulation Model Thickness Prediction Model Geometric Accuracy Control Fracture Prediction Desired Process Control Goals NSF I/UCRC Planning Meeting Slide 7

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 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 Slide 8

9. Dieless Incremental Sheet Forming Back Up Slides NSF I/UCRC Planning Meeting Slide 9

9. Dieless Incremental Sheet Forming Desktop Gen-1 NSF I/UCRC Planning Meeting Gen-2 Slide 10