International Journal of Materials, Mechanics and Manufacturing, Vol. 2, No.

3, August 2014

Experimental Cases in Aluminium Foils by Dieless

Process and His Comparison with Others Conventional
Sheet Metal Forming Process
Gabriel J. Paramo and Adrian J. Benitez

AbstractIncremental sheet forming by the method of single

point incremental forming Dieless, is a widely studied process,
experimented and developed in countries with high
manufacturing technologies, with friendly costs when the
productive configuration in a productivity system is based in
small production batches. Previously mentioned, this work
pretends to develop experimental cases in aluminum foils with 1
mm- thickness, and some specific process parameters, the
analysis of forming limit curve (FLC), with the objective to
emphasizes in this innovative method based in CAD-CAM
technologies, compare with other analogous process of
deformation sheet metal like embossing, deep drawing, stamping,
spinning, superforming, take correct decisions about the
viability and applicability of this process (Dieless) in a particular
industrial piece, which responses to the necessities of productive
configurations mentioned and be highly taken like a
manufacturing alternative to the others conventional process of
forming sheet metal , for systems with slow batches production.

Fig. 1. Dieless representative illustration.

The purpose of this paper is to study experimental cases

associated with a particular one, which is due to a conical
geometry, to analyze the deformation of the same building
through the forming limit curve diagram (FLD). The
formability of a sheet or foil, such as its ability to be deformed
by forming a specific process from its original form to the
final piece flat, without the occurrence of failure in the
material, either broken or necking, the ease of a material to
plastic deformation without defects [4]-[6].
The above is intended to orient the investigation to work
with geometries that approximate and apply to a principle or
Industrial application case, making decisions on the viability
argued acceptable or not the process and have a specific
comparison with the filling process. With the ultimate goal of
making a functional prototype tested mechanical and dynamic
evaluations of this process, to ensure the functionality and
usability of a product manufactured under this innovative
manufacturing process such as Dieless.

Index TermsCAD-CAM, dieless, forming limit diagram

curves (FLD), toolpath.

I. INTRODUCTION
The incremental forming process by the method of
supporting a single point Dieless (SPIF), involves the
transformation of a metal sheet by a mechanical stress which
produces a progressive deformation in the sheet. The process
is done in several stages: it starts with a CAD (Computer
aided design) modeling which represents the experimental
geometry in three dimensions of the particular piece, the
second stage is fed by the CAD file, assigning parameters
such as the advance, RPM (Rev/Min), diameter tool, step
depth, to a CAM (Computer aided manufacturing) system,
you get a programming tool path, expressed in machine code
known as G code1. This code is entered into a machine with
CNC technology which reproduces the toolpath on the surface
and deforms the end of the geometry piece, which is the final
stage. Fig. 1, illustrates a representative form of this process.
The incremental deformation process without matrix
(Dieless), is a recent process (its inception refer to 1994)
[1]-[3] with respect to other techniques of conventional foil
strain such as embossing, stamping, superforming and
Manuscript received January 20, 2014; revised March 21, 2014.
The authors are with the Manufacturing Department at EAFIT University,
Medellin, Colombia (e-mail: {gparamo, abenite2}@eafit.edu.co).
1
G-Code: The G code is a language trough which people can tell
computer-controlled machine tools do and how. These what and how are
defined mostly by instructions on where to move, how fast moving and
toolpath or follow. Typical machines are controlled is code are milling
machines, cutting machines, lathes and 3d printers.

DOI: 10.7763/IJMMM.2014.V2.129

hydroforming, which are costly and involve working tooling

and high volume production runs for its construction and
operation.

210

Fig. 2. Geometry associated an experimental case.

II. METHODOLOGY
For the experimental procedure followed the next

International Journal of Materials, Mechanics and Manufacturing, Vol. 2, No. 3, August 2014

hypothesis sheet thinning located at this point, which together

with the formability angle are two extreme conditions which
result in the presentation physically cracks and long shapes as
shown in Fig. 6, which is then analyzed.

methodology:
As a starting point, we determine the geometry of the part:
settled for the experimental case geometry conical differential
characteristic angle formability, as shown in Fig. 2.
The blank plates or training are square sheets of 100 mm
1100 aluminum side and 1 mm thick.
For construction of diagrams-forming limit curves, it was
necessary to perform the marking of the pieces, which
consists of a grid of continuous circles of 5 mm diameter. In
Fig. 3, this system can be observed on the piece of lined,
which was made into a laser marking machine.

Fig. 5. Visual aspect for a formed and fractured piece from different
experimental cases.

Fig. 3. Marking system plates under laser technology

Once the marking of parts is carried generation strategy and

toolpath: The helical toolpath responds to a helical scan is
made along the inner surface of the sheet deformed, it was
necessary to work with CAM software.
Was subsequently carried determining process parameters
Dieless. Both for design (CAD) of the experimental geometry,
generating cutting strategies CAM, and assigning values to
parameters involved in the process, it has high engineering
software.
Machine Preparation and installation: Dieless device, Fig.
4 shows the assembly of the part Dieless device.

Fig. 6. Cracks and localized thinning from fracture piece in aluminum foils.

The cracks occur as a result of residual stresses produced in

the work piece. These residual stresses are a major feature in
the sheet forming operations and are commonly caused by
non-uniform deformation during forming, causing a partial
distortion when cut, and producing said cracking [5].
The parameters presented in Table I, are best suited and
recommended for this geometry work, several authors in their
research and procedures used tool diameters between 8 and
12 mm, high RPM and feed rates relative to the depth of cut [7]
- [13], has been shown that the lower step, the surface quality
and formability of the material are much better, considering
cutting times are greater.
TABLE I: NOMINAL VALUES PARAMETERS FOR EXPERIMENTAL CASES
SPIF PROCESS

FORMING PARAMETERS PROCESS

Tool diameter (mm)
10
RPM
3500
Cutting feed (mm/min)
5000
Step depth (mm)
1

Fig. 4. Assembly of a piece in Dieless device with CNC machinelaboratories EAFIT University.

Observing the process parameters shown in Table I, it is

important to note that the progress, which has a value of 3500
mm/min, corresponds to approximately 50% of the maximum
speed of the CNC machining center used (maximum advance
machining center used 7200 mm / min). The strategy or tool
path tool path was helical steps and 1 mm depth.

III. RESULTS AND DISCUSSION

The testing and subsequently different experimental cases
which are detailed below.
The formation and fracture criterion answers the
formability evaluation part as mechanical forming; Fig. 5
shows the visual appearance of a formed part and a fractured
part formation.
From a distance of 15 mm depth (Approx.), for different
cases and different proofs, measured from the surface of the
workpiece, such crack had fracture in the same place. As a

FLD Curve Construction

The diagram limit shaped for a sheet, is a graphical
representation of the boundaries of main strains, where it may
arise failure in plastic deformation during the forming process.
From the above definition, we can identify areas along the
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International Journal of Materials, Mechanics and Manufacturing, Vol. 2, No. 3, August 2014

positive due to stretching occurs and less deformation can be

negative or positive, as can occur when stretched narrowing
(Poisson effect) the initial specimen. It can be stated that
under bounded or curved line are safe values and above the
fault. For the particular case, there is an extreme value for
which the strain is 80% higher and lower distortion is -20%,
suffered in aluminum alloy 1100, which represents a good
plastic deformation of the material obtained by through this
process. The formability of a particular material will be better
when the FLD curve is higher [6].
Comparing analogous to the process of drawing, on what is
commonly used in the manufacture of hollow pieces such as
this geometry experienced in this work and responds to the
fundamental principle of sheet metal processing, are shown in
Table III, a general comparative Dieless process [14]-[21]
and stamping-drawing, for performing the piece addressed in
this paper.

deformed surface of the test piece, and account for the

formability of the material.
For construction of the limit curves forming or diagrams
FLD is necessary to calculate the result of the conventional
deformation suffered by the piece, which is the relationship
between the change in length of a specimen in the direction
that applies strength and the original length of the sample
considered [6]. In Equation (1) shows how to calculate it:

%Stretching

Lf Lo
100
Lo

(1)

From the equation above, it is important to take data in

different areas of the deformed part, before and after the
process in order to obtain readings of initial lengths Lo , and
final lengths of the same Lf .
Data for Construction of Curves FLD
Table II shows the data measured once deformed the
workpiece, with the aid of the grid circles, ellipses now to
determine the major and minor deformities in different areas
of the piece, to analyze the formability of it.

TABLE III: PROCESS COMPARATIVE - CONVENTIONAL SHEET METAL

FORMING PROCESS AND DIELESS

TABLE II: DATUM FOR FLD CONSTRUCTION CURVE

Datum
0
1
2
3
4
5
6
7
8
9
10

Datum for FLD construction curve (Plate thickness 1mm)

Major Length (mm) Minor Length (mm)
% Major strain % Minor strain
3
2,5
20%
0%
2,9
2,45
16%
-2%
5
2,2
100%
-12%
8
2,6
220%
4%
6,8
2,25
172%
-10%
6,5
2,3
160%
-8%
7
2,5
180%
0%
7
2,35
180%
-6%
6,8
2,65
172%
6%
7,2
2,8
188%
12%
4,5
2
80%
-20%

With the overview of processes of forming two sheet metal

details the analogy to perform the experimental part, for
which respective comparisons are described based on the
observations in Table IV which shows a comparison of the
performance part case study worked through the other
processes in question, according to the calculations made for
the part geometry and particular design parameters for the
filling process [10]-[25], and any of the parameter values
specified for Dieless.

The above data obtained were plotted on the graph of FLD

curve for the product obtained as show in the next figure:

TABLE IV: COMPARATIVE TO OBTAIN GEOMETRIC PART BY DIELESS AND

STAMPING-DRAWING PROCESS

Fig. 7. Forming limit diagram for piece with 1 mm thickness.

As seen in Fig. 7, shown at the top right, a circular

geometrical figure, shaded continuous contour which
represents the circle inscribed in the aluminum foil before
being deformed, and dashed ellipse in which due to the
two-dimensional geometry of the elongated circle (ellipse)
once the piece has been deformed. The dimensions of the
coordinates shown with the letter b, the lengths are larger and
smaller, respectively, which are the final readings (Lf) to
determine the percent elongation and major and minor strains
required for the construction of the curve obtained FLC
above.
Greater deformation has been shown in axis Y, always

According to the above Tables III and IV, that for

high-speed production cycles or production rate for the
manufacture of the part studied in this work, the deep-drawing
and spinning process would be the most convenient
alternative, but requires investment in tooling and tooling to
ensure the formability of the sheet, such as matrix, blank
holders to ensure the strength and pressure of the process
described above. Dieless-SPIF process, contrary to what
stated above, does not require blank holders, receivers and
since the force and pressure in the process are relatively low
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International Journal of Materials, Mechanics and Manufacturing, Vol. 2, No. 3, August 2014

[10]-[25], only one pass is required to obtain the shaping of

the work piece but the speed is much lower compared to the
stamping drawing process.

IV. CONCLUSIONS
As a conclusive principle and fundamental objective of this
work was obtained aluminum sheets 1100, a conical piece
with an angle of formability obedient taper experimental
geometry. With the above provides a starting point and also
an important step in finding a near future implementation of
the process and a piece of industrial applicability.
Dieless-Spif process is a relatively new process compared
with the deep drawing/superforming/stamping/spinning
pieces, allows greater flexibility in the design of various
surfaces, even complex, requires high labor costs in tooling
and dies. Parts formability is acceptable, as demonstrated in
the results of this work.
ACKNOWLEDGMENT
This work was supported by the EAFIT Manufacturing
department and its laboratories. The authors thanks EAFIT,
production technologies group and its I&D program.
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Gabriel J. Paramo is a mechanical engineer who has

received his master degree in education. He is an advisor
of CAD-CAE-CAM systems. He is currently full-time
teaching in the Department of Production and design
Engineering, BITS Ltd. He is also a research associate in
the research group production technologies. His
research interests include industrial applications CAD
CAE CAM systems, software tools for the design of shoe
lasts "Horma CAD" Development of a CAD / CAM software - platform for
working machinery manufacturing, which emphasizes in metallic sheet
transformation process.

Adrian J. Benitez received his title as a production

engineer in 2009 at EAFIT University, he is a design
life cycle product specialist in 2013 and master
engineer candidate (Actually) in the same University.
He has been a researcher associate in the research group
production technologies since 2009. He is a professor
in the Manufacturing Department at EAFIT University,
and a researcher associate in Colciencias group,
Colombia.