Numerical Study on Single Point Incremental Sheet Metal Forming Process
-Single Point Incremental Sheet Forming (SPIF) is an innovative forming approach for sheet materials. In this process, the forming tool is moved along a predefined tool path which is a series of contour constructed a final shape of product by using numerical controlled technology. This paper investigated finite element analysis simulation to predict the mechanical failures in single point incremental sheet metal forming (SPIF). In the present paper, some of these aspects, namely, the phenomenon of the wall thickness overstretch along depth and the effect of the tool path on the distribution of the wall thickness using finite element simulations etc. are investigated. It is observed from the analysis that the single point incremental sheet metal forming is very much time consuming and also the depth of stretch with different step size and tool diameters have been implemented.
Deformation Mechanism Analysis of Single Point Incremental Sheet Metal Forming
Abstract Single point incremental forming (SPIF) is a new innovative and feasible solution for the rapid prototyping and the manufacturing of small batch sheet parts. The process is carried out at room temperature and requires a CNC machining centre, a spherical headed tool and a simple support to fix the sheet being formed. In incremental Sheet Metal Forming the blank is incrementally deformed in to a desirable shape by hemispherical or ball nose tool traveling along a prescribed path. Due to the various advantages including the reduced production cost and time of prototypes, improved formability, easy modification of part design etc. the ISF is being popular as a new innovative forming technology. In the present study experiments were conducted to analyze the deformation mechanism of commercial aluminum alloy. Beside this analysis result of the effect of forming angle, step size, tool diameter on formability and wall thickness distribution are presented.
Finite element simulation of multi-point sheet forming process based on implicit scheme
Abstract Multi-point forming (MPF) is a flexible manufacturing technique for three-dimensional sheet metal forming. The deformation of material and contact boundary in multi-point forming processes are very different from those in traditional stamping processes. In this paper, an incremental displacement approach on the basis of updated Lagrangian formulation and elastic–plastic material model for finite element simulation of MPF process is described. An effective algorithm for the integration of stresses is introduced. The multi-point, discontinuous contact interface between sheet and tools is modelled with contact finite element based on the penalty method and on the Coulomb non-classical friction law of elastic–plastic formalism. An integration algorithm of the frictional contact constitutive equations is derived. Forming processes of sheet metal are analyzed by using a new finite element code developed by the authors. The results of numerical examples show good general coincidence with those of the experiments and explicit/elastoplastic analysis reported in the literature. Two representative examples of application in MPF are also presented in order to show the applicability of the algorithm.