A numerical analysis on forming limits during spiral and concentric single point incremental forming

Sheet metal forming is one of the major manufacturing industries, which are building numerous parts for aerospace, automotive and medical industry. Due to the high demand in vehicle industry and environmental regulations on less fuel consumption on other hand, researchers are innovating new methods to build these parts with energy efficient sheet metal forming process instead of conventionally used punch and die to form the parts to achieve the lightweight parts. One of the most recognized manufacturing process in this category is Single Point Incremental Forming (SPIF). SPIF is the die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any process time to plastic deformation zone. In the present work, finite element method (FEM) is applied to analyze the forming limits of high strength low alloy steel formed by single point incremental forming (SPIF) by spiral and concentric tool path. SPIF numerical simulations were model with 24 and 29 mm cup depth, and the results were compare with Nakajima results obtained by experiments and FEM. It was found that the cup formed with Nakajima tool failed at 24 mm while cups formed by SPIF surpassed the limit for both depths with both profiles. It was also notice that the strain achieved in concentric profile are lower than that in spiral profile.

[1]  Niels Bay,et al.  Single‐point incremental forming and formability—failure diagrams , 2008 .

[2]  Markus Bambach,et al.  Investigation into a new hybrid forming process: Incremental sheet forming combined with stretch forming , 2009 .

[3]  Ricardo J. Alves de Sousa,et al.  Evaluation of the Enhanced Assumed Strain and Assumed Natural Strain in the SSH3D and RESS3 Solid Shell Elements for Single Point Incremental Forming Simulation , 2012 .

[4]  Joost Duflou,et al.  Asymmetric single point incremental forming of sheet metal , 2005 .

[5]  Abstr Act,et al.  Incremental sheet forming process modelling - limitation analysis , 2007 .

[6]  I. Cerro,et al.  Theoretical and experimental analysis of the dieless incremental sheet forming process , 2006 .

[7]  P. Hodgson,et al.  Necking and fracture of advanced high strength steels , 2011 .

[8]  Markus Bambach,et al.  Modeling of Optimization Strategies in the Incremental CNC Sheet Metal Forming Process , 2004 .

[9]  Giuseppe Ingarao,et al.  A sustainability point of view on sheet metal forming operations: material wasting and energy consumption in incremental forming and stamping processes , 2012 .

[10]  Lirio Schaeffer,et al.  Incremental forming process strategy variation analysis through applied strains , 2014 .

[11]  Janez Kopac,et al.  Incremental sheet metal forming on CNC milling machine-tool , 2005 .

[12]  Karl Kuzman,et al.  Deformations and forces analysis of single point incremental sheet metal forming , 2009 .