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dc.contributor.authorGupta, Pranaven
dc.description.abstractSingle point incremental forming (SPIF) is a dieless sheet metal forming technique that can manufacture customised sheet metal components in a cost-effective manner. However, the process is still in the developmental phase and hasn't been utilised industrially due to low geometrical accuracy, fracture at high wall angles and long cycle times. The goals of this research are to study the feasibility of the already existent strategies to eliminate geometrical errors and enhance formability and to, introduce a methodology to successfully generate vertical walls with the least geometrical errors and thickness variation within the manufactured component. The impact of friction on sheet interface and formability is reported by recording the temperature obtained by increasing the tool rotation speed and feed rate. A flat tool is used in the study and an upper limit of the tool rotation speed is reported. The limit is much lower than the hemispherical tool reported in the literature and two heat generation zones is the justification. High tool rotation speed and feed rate are found to reduce the geometrical errors but still are unacceptable. Multi-stage strategies such as the conventional downward, DDDU and IO-OI are implemented to manufacture a C-channel designed to support a plane fuselage for vibration testing. Tunnel strategy is also employed. Vertical walls are only conceivable using a conventional downward strategy and a series of steps followed for the toolpath development are reported in the form of an algorithm. The results show that the developed component is affected by severe geometrical inaccuracies and extreme thickness variation. Cost analysis reveal high costs associated with multi-stage forming in the design stage. Finally, it is concluded that cost-effective and industrially acceptable flat base geometries are inconceivable through SPIF. The apparatus of Two Point Incremental Forming (TPIF) is modified and a new tool path strategy is developed to manufacture the vertical walls. The results show that the novel strategy is capable of manufacturing vertical walls with much lower thickness variation and geometrical errors. The developed method is cost-effective and easy to implement but requires a die.en
dc.relation.ispartofseriesCanadian thesesen
dc.rightsQueen's University's Thesis/Dissertation Non-Exclusive License for Deposit to QSpace and Library and Archives Canadaen
dc.rightsProQuest PhD and Master's Theses International Dissemination Agreementen
dc.rightsIntellectual Property Guidelines at Queen's Universityen
dc.rightsCopying and Preserving Your Thesisen
dc.rightsThis publication is made available by the authority of the copyright owner solely for the purpose of private study and research and may not be copied or reproduced except as permitted by the copyright laws without written authority from the copyright owner.en
dc.rightsAttribution 3.0 United Statesen
dc.subjectGeometrical errorsen
dc.subjectVertical wallsen
dc.subjectCost analysisen
dc.titleManufacture of vertical walls with asymmetric incremental sheet formingen
dc.contributor.departmentMechanical and Materials Engineeringen
dc.embargo.liftdate2019-10-02's University at Kingstonen

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Queen's University's Thesis/Dissertation Non-Exclusive License for Deposit to QSpace and Library and Archives Canada
Except where otherwise noted, this item's license is described as Queen's University's Thesis/Dissertation Non-Exclusive License for Deposit to QSpace and Library and Archives Canada