Finite element method study of incremental sheet forming for complex shape and its improvement

Abstract In order to improve the incremental sheet forming process for the product of complex shape (e.g. human face), a combination of both computer-aided manufacturing (CAM) and finite-element modelling (FEM) simulation, is implemented and evaluated from the histories of stress and strain value by means of finite-element analysis. Here, the results, using ABAQUS/Explicit finite-element code, are compared with forming limit curve at fracture in order to predict and improve the forming conditions by changing process variables of tool radius, tool down-step, and friction coefficient according to the orthogonal array of Taguchi's method. First, the CAM simulation is used to create cutter location data. This data are then calculated, modified, and exported to the input file format required by ABAQUS through using MATLAB programming. The FEM results are implemented for negative incremental sheet forming and then investigated by experiment.

[1]  Giuseppina Ambrogio,et al.  An analytical model for improving precision in single point incremental forming , 2007 .

[2]  Betzalel Avitzur,et al.  Analysis of power spinning of cones , 1960 .

[3]  N. Hayat,et al.  The effect of variation in the curvature of part on the formability in incremental forming: An experimental investigation , 2007 .

[4]  Heung Nam Han,et al.  A ductile fracture criterion in sheet metal forming process , 2003 .

[5]  Serope Kalpakcioglu,et al.  A Study of Shear-Spinnability of Metals , 1961 .

[6]  M. Shim,et al.  The formability of aluminum sheet in incremental forming , 2001 .

[7]  S. Clift,et al.  Fracture prediction in plastic deformation processes , 1990 .

[8]  J. J. Park,et al.  Effect of process parameters on formability in incremental forming of sheet metal , 2002 .

[9]  Young-Suk Kim,et al.  Prediction of forming limits for anisotropic sheets containing prolate ellipsoidal voids , 2003 .

[10]  Ghulam Hussain,et al.  An experimental study on some formability evaluation methods in negative incremental forming , 2007 .

[11]  Dong-Yol Yang,et al.  Improvement of formability for the incremental sheet metal forming process , 2000 .

[12]  Y. S. Kim,et al.  A parametric Study in Incremental Forming of Magnesium Alloy Sheet , 2008 .

[13]  Kozo Osakada,et al.  Simulation of plane-strain rolling by the rigid-plastic finite element method , 1982 .

[14]  M. Muzzupappa,et al.  Influence of some relevant process parameters on the dimensional accuracy in incremental forming: a numerical and experimental investigation , 2004 .

[15]  C. H. Lee,et al.  New Solutions to Rigid-Plastic Deformation Problems Using a Matrix Method , 1973 .

[16]  N N Powell,et al.  Incremental Forming of Flanged Sheet Metal Components Without Dedicated Dies , 1992 .

[17]  R. Hill.  Theoretical plasticity of textured aggregates , 1979, Mathematical Proceedings of the Cambridge Philosophical Society.

[18]  F. Micari,et al.  Influence of mechanical properties of the sheet material on formability in single point incremental forming , 2004 .

[19]  Y. Tomita.  Simulations of Plastic Instabilities in Solid Mechanics , 1994 .

[20]  H. Iseki,et al.  An approximate deformation analysis and FEM analysis for the incremental bulging of sheet metal using a spherical roller , 2001 .

[21]  C. Sathiya Narayanan,et al.  Some analysis on stress and strain limit for necking and fracture during forming of some HSLA steel sheets , 2007 .

[22]  Bernard Budiansky,et al.  Analysis of Sheet Metal Stamping by a Finite-Element Method , 1978 .

[23]  L. Gao,et al.  A novel method to test the thinning limits of sheet metals in negative incremental forming , 2007 .

[24]  H. W. Swift.  Plastic instability under plane stress , 1952 .

[25]  K. Debray,et al.  An efficient pseudo-inverse approach for damage modeling in the sheet forming process , 2004 .

[26]  R. Hill,et al.  On discontinuous plastic states, with special reference to localized necking in thin sheets , 1952 .

[27]  Ann Bettina Richelsen,et al.  Elastic—plastic analysis of the stress and strain distributions in asymmetric rolling , 1997 .

[28]  Dorel Banabic,et al.  Simulation of the hydroforming process using a new orthotropic yield criterion , 2004 .