SPIF: Exploring Viability in a Design for Manufacture context
Bartlett School of Architecture M.Arch Design for Manufacture Tutors: Dr Christopher Leung & Gary Edwards Thesis Supervisor: Nick Callicott RS 102 BENVGF13: Thesis Portfolio Syazwan Hanif
Initial Design Workshops: ErgoDynamism
Referenced from New Metric Data, David Adler
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450
513
570
Anthropometric study of my own body proportions
Tracking of head & eye movement whilst working in different configurations
Hyperboloid that responds to objects moving towards & away from it
Render of final hyperboloid assembly
Photograph of actual hyperboloid assembly
CAD of hyperboloid prototype
Exploded hyperboloid assembly
Render of hyperboloid prototype
3D Print of hyperboloid prototype
Hyperboloid responding to changes in distance of objects to the ultrasound sensor
Electronic wiring of Arduino and various peripherals
Process Development Simulation of SPIF toolpath
Behera et al. (2017), Representation of process of single point incremental forming.
CAM Simulation of SPIF toolpath
Render of expected incremental form
Computer-Aided Manufactue (CAM) simulation of similar SPIF toolpath
Single Point Incremental Forming (SPIF) A sheet metal blank is deformed incrementally into a desired shape by the action of a hemispherical tool following a defined tool path forming a final part geometry. (Behera et al, 2015)
Designed a work holding system to hold material to be formed through SPIF
30mm
297mm
35mm M8 Bolts
Rendered Exploded view of sheet metal blank & work holding system
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8
9
A
A
297
8
2
y
7
B
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5
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250
C
600
420
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B
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Parts List D
E
Item
Qty
1
2
Part Number ALU002
2
2
ALU001
30mm x 30mm x 600mm Aluminium Profile
Aluminum
3
2
ALU003
600mm Clamping Piece
Aluminum
4
4
BRACKET _30X30
5
2
ALU004
237mm Clamping Piece
Aluminum
6
26
M8 T-Nut
T_NUT_M8
Steel
7
2
ALU005
600mm Aluminium Profile Clamp Support
Aluminum
8
6
91290A43 Black Oxide Alloy Steel Socket Head, M8 x 8 1.25mm thread, 35mm length
Steel
M8 Washer
Steel
F
9
6 1
Description
D
Material
30mm x 30mm x 237mm Aluminium Profile
Aluminum
Steel
M8 Washer 2
3
E
Dept.
DFM
Technical reference
Created by
Syazwan Hanif
Document type
3/3/18
2D Drawing
Title
Document status
DWG No.
SPIF_Clamp
4
Approved by
F Rev.
5
6
7
Date of issue
Sheet
8
1/1
Single Point Incremental Forming Workholding System
420mm
1
Datum set in the G-code at the middle of the work piece
x
Speculative forms and toolpaths of panels formed using SPIF
Spindle spinning helps alleviate uneven wear on the toolhead through friction Feed rate of the tool that balances formability & forming time
Calibration of physical to digital tool in CAM environment
28mm Hemispherical-head tool
Decides the feed rate of the tool when translating in the z-axis
Incremental forming occurs from outside-in to aid in formabiliy Rate of change of depth in z-axis during forming process
Forming parameters from Computer-Aided Manufacturing environment
28mm Hemispherical-head tool in Haas TM-3P Milling Machine
Forming Accuracy and Formability Toolpath simulation for material formability test
Incrementally formed 2mm mild steel 0.4mm stepover morphed spiral toolpath No flat area detection
Incrementally formed 2mm mild steel 0.4mm stepover morphed spiral toolpath Flat area detection
Different levels of formabiity affected by different toolpath parameters. Learning through experimentation which toolpaths give forms closest to the CAD
1mm AA1050, formed side
1mm CR4 Mild Steel, formed side
1mm AA1050, opposite side
1mm CR4 Mild Steel, opposite side
Differences in finish and forming marks given by using different types of sheet metal
Form Removal
Milling toolpath to cut out SPIF form from sheet metal blank on CNC mill
Post-SPIF and cut out with an endmill following a contour toolpath
Model of digital die with perimeter border to indicate geometry for removal
Sheet metal blank post-SPIF
SPIF form placed on waterjet bed and cut out following DXF toolpath
Remaining sheet metal blank with calibration markers
Forms cutout using the waterjet DXF for waterjet cutting
Edge Interfaces Due to springback, forms are not planar along its perimeter and thus are forced together in a vice
Formed elements clamped together to be welded
Formed elements being tig welded together
Symmetrical SPIF elements formed, cutout and welded together along a common perimeter.
Studio Pod: Group Project
SPIF toolpath
SPIF to act as part of a series of sheet metal forming processes
Solid model
3D scan mesh converted to a surface
SPIF into hydroformed part achieved through remodeling hydroformed part in CAD environment through use of 3D Scanning
Work holding system with calibration points
CAD model of SPIF form designed into the hydroformed piece
Toolpath of SPIF form designed into hydroformed piece
Created a surface model from a mesh obtained through 3D Scanning Used scan to obtain a solid model representation of the hydroformed object.
SPIF form is designed into the solid model that takes into account the curvature of the hydroformed part.
SPIF form is formed into the actual hydroformed part by the Haas TM-3P
Viability of Incremental Sheet Metal Forming as a Design and Manufacturing Process. How does Incremental Sheet Metal Forming change the landscape of Design for Manufacture?
Larger workholding system to maximize forming area of Haas TM-3P
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370
560
1000
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56 0
Installation of Workholding system for SPIF at extents of Haas 3M-TP 3 00
HAAS TM-3P Milling Machine Forming area: 1000mm x 500mm Effective area: 950mm x 450mm
Spindle speed
Tool Diameter
Feed rate
Stepover Size
Parameters that affect forming and formability
Translating the digital die into a formed object through CAM toolpaths
New designed forms to create double shell incremental vessels and their corresponding toolpaths
Problems with scale
1st large scale SPIF with maximum depth of 200mm
Failed attempt to remove form using CNC Milling Machine
Large deformation along the edges as they were not clamped down
Milling Toolpath to cut out form from sheet metal blank
Overwhelming force created through SPIF process caused the frame to fail
Datum must be marked out on sheet metal blank so as to ensure digital toolpaths lines up with sheet metal blank
Large frame size means that the datum is set as the middle of the work piece, as unable to reach the corners for calibration with the toolhead
Tool wear due to tool material not being harder specificatiion than sheet metal blank Material failure due to a forming angle that is too steep
Forms held together by clamps to be welded
Render of CAD model of individual surfaces do not align.
Forms spot welded together to see if they would line up along the edge
Physical incremental formed individual surfaces do not align.
Forms are free-form modelled with edges corresponding with final edge to ensure deformation is similar along the edges
Slats of waterjet removed to make way for the SPIF forms within the frame
Forms are nested using the frame for it to be cut out on the waterjet
SPIF forms nested within frame and cut out using the waterjet, to ensure edges align
Nested remaining sheet metal blanks after forms have been waterjet cut out
Formed sheet steel before edges have been cleaned & prepared for brazing
Form aligns due to considered CAD
Form being brazzed together after being spot welded in place so as to keep its alignment
Two forms with differing depths and the same perimeter are formed and cut out to be brazzed together to form a vessel of formed sheet metal Edges are easily brazed together due to the similar deformation of both upper and lower forms