Finite element simulation of two-point incremental forming of free-form parts

Document Type : Research Paper

Authors

Department of Mechanical Engineering, University of Birjand, Birjand, Iran

Abstract

Two-point incremental forming method is considered a modern technique for manufacturing shell parts. The presence of bottom punch during the process makes this technique far more complex than its conventional counterpart i.e. single-point incremental forming method. Thus, the numerical simulation of this method is an essential task, which leads to the reduction of trial/error costs, predicts the tearing of sheet and investigates various aspects of this complex method. Most of the previous works regarding numerical simulation of incremental forming method have concentrated on the single-point type of this technique. Moreover, all of these simulations have considered simple geometries like truncated cone, truncated hemisphere and truncated regular pyramid, which are based on well-known mathematical functions. In this study, a novel simplified procedure is presented for the finite element simulation of two-point incremental forming of free-form parts. The procedure is based on the extraction of tool-path points by using CAM software and the finite element model. In the current study, it will be shown how simulated results can be applicable for gaining useful information about the tearing of deforming sheets, selecting suitable numerical machines for practical forming processes and the deformation quality of sheets.

Keywords


1. I. Bagudanch, L.M. Lozano-Sánchez, L. Puigpinós, M. Sabater, L.E. Elizalde, A. Elías-Zúñiga, Manufacturing of polymeric biocompatible cranial geometry by single point incremental forming, Paper presented at the Procedia Engineering (2015) 267-273.
2. M. Tera, O. Bologa, R.E. Breaz, S.G. Racz, Theoretical and experimental researches regarding multilayer materials used for incremental forming, Applied Mechanics and Materials 555 (2014) 413-418.
3. T. Trzepiecinski, B. Krasowski, A. Kubit, D. Wydrzynski, Possibilities of application of incremental sheet - forming technique in aircraft industry, Scientific Letters of Rzeszow University of Technology - Mechanics 1 (2018) 87-100.
4. A.G. Parande, V.G. Bhalke, D.N. Kanke, R.M. Gaikwad, P.K. Bhoyar, Innovative single point incremental forming, VJER-Vishwakarma Journal of Engineering Research 3 (2017) 212-216.
5. P. Martins, N. Bay, M. Skjødt, M. Silva, Theory of single point incremental forming, CIRP Annals-Manufacturing Technology 57 (2008) 247-252.
6. K. Jackson, J. Allwood, The mechanics of incremental sheet forming, Journal of materials processing technology 209 (2009) 1158-1174.
7. H. Iseki, K. Kazunori, S. Sakamoto, Forming limit of flexible and incremental sheet metal bulging with a spherical roller, Advanced Technology of Plasticity 3 (1993) 1635-1640.
8. M. Silva, M. Skjødt, N. Bay, P. Martins, Revisiting single-point incremental forming and formability/failure diagrams by means of finite elements and experimentation, The Journal of Strain Analysis for Engineering Design 44 (2009) 221-234.
9. A. Zahedi, B. Mollaei-Dariani, M.R. Morovvati, Numerical and experimental investigation of single point incremental forming of two layer sheet metals, Modares Mechanical Engineering 14 (2014) 1-8.
10. A. Mulay, S. Ben, I. Syed, A. Ben, Artificial neural network modeling of quality prediction of a single point incremental sheet forming process, Advanced Science and Technology Letters 147 (2017) 224-250.
11. R. Perez-Santiago, A. Fiorentino, R. Marzi, C.A. Rodriguez, Advances in simulation of two point incremental forming, AIP Conference Proceedings (2011) 183-188.
12. Q.C. Wang, H.H. Hu, J.H. Wu, J. Cao, Research on Forming Accuracy of Two Point Incremental Forming for Aluminium 1060, Advanced Materials Research (2014) 1725-1729.
13. N. Devarajan, G. Sivaswamy, R. Bhattacharya, D. P. Heck, M. A. Siddiq, Complex incremental sheet forming using back die support on aluminium 2024, 5083 and 7075 alloys, 11th International Conference on Technology of Plasticity Procedia Engineering 81 ( 2014 ) 2298 – 2304.
14. S. H. Haight, An anisoropic and asymmetric material model for simulation of metals under dynamic loading, PhD Thesis, George Mason University, 2015.