Headlight Fairings
This case study demonstrates the benefits of a dieless forming method for small batches of parts, and the ability for ISF to be used when a production run has ended and a desired die can no longer be sourced.
Background: proof of concept for industry standard components
The motorcycle headlight fairing is an example of an industry standard automotive component, which is why it was chosen to demonstrate the capabilities of single-point incremental forming in a recently-submitted paper from The University of Sheffield.
By documenting, analysing and disseminating findings relating to the forming of industry standard components, it is hoped that future improvements to ISF's key drawbacks (particularly dimensional accuracy) will increase the uptake of ISF in industry.
Key Points
CAD geometry created for fairing design
Comparison between formed and designed geometries in the ZY cross section
3D laser scan deviation plot of formed geometry
Finished part
Benefits
ISF offers the cheapest method of producing many standard components no longer in production.
The small-batch flexibility of the process would facilitate contributions from small businesses and hobbyists.
The use of commonly-used materials like steel in ISF has already been widely investigated, demonstrating good formability.
Viability
Geometry may have to be adapted slightly to be produced by ISF. For example, wall angles cannot exceed the maximum forming angle of the material in use.