A Study on Dieless Incremental Sheet Metal Forming Using Water Jet Technology

Abstract

A new method of sheet metal forming, water jet incremental sheet metal forming (WJISMF) is presented. We give the schematic illustration of WJISMF system, which includes high pressure system, NC machine, control system, water recycle system, and some attachments, and then the virtual prototype of the system is designed. To predict the whole deformation process, some simulations are carried out. Firstly, fluid structure interaction simulation for WJISMF is performed. The water jet is modeled and simulated with a computational fluid dynamics (CFD) approach, while for the material flow in the workpiece a finite element analysis (FEA) is used. Secondly, the relationship between the workpiece material deformation and nozzle diameter, and the relationship between deformation and water pressure are presented. Thirdly, the fluid structure interaction simulation model is simplified to the structure simulation model, by adopting shell 181 element and using a pressure acting on the workpiece directly instead of the CFD model. Finally, a simulation for forming a cone box is done using the simplified model. The simulation provides a powerful rationale for the practical application of WJISMF.

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

“…Teymoori et al [70] used a coupled Eulerian-Lagrangian approach to simulate the WJISF forming process of a conical part using the three-dimensional Finite Element Method (FEM). The mechanics of liquid/solid interaction in WJISF were studied by Kai et al [71] using a finite element-based numerical simulation. They modelled and simulated the water jet with a Computational Fluid Dynamics (CFD) approach.…”

“…In patent CN201110347675, He et al [73] developed a water jet apparatus that rotates during machining and oscillates within a set range so that a high-pressure water column oscillates within the set range and rotates axially around the axis of the water column to complete the forming process. a conical part using the three-dimensional Finite Element Method (FE of liquid/solid interaction in WJISF were studied by Kai et al [71] ment-based numerical simulation. They modelled and simulated t Computational Fluid Dynamics (CFD) approach.…”

Water jet incremental sheet metal forming: a critical state-of-the-art review and a proposal for technological windows

“…Many papers, of course, fell into more than one domain. Emmens 2007 [11] Accepted manuscript / Final version He 2011 [20] Luo 2012 [21] He 2013 [22] Li, H. 2013 [23] Li, J. 2014 [24] Li, H. 2014 [25] Wei 2015 [26] T7 Shenyang Aerospace University Zhang, L. 2013 [27] Zhang, L. 2013 [28] Zhang, L. 2015 [29] T8 Xi'an Jiaotong University Zhang, Q.…”

“…The scientists in Team 6 came from six Chinese universities, and spent 5 years working on a project to form sheet metal using a high-pressure WJ. Their approach was quite comprehensive and started quite conventionally with several theoretical and numerical studies during the early years [19][20][21], followed by experimental studies [22] [24], including real-world part production [23] [25] [26].…”

“…Simulations showed that plastic deformation depth increased as WJ pressure and nozzle diameter increased, or as sheet metal thickness decreased. The authors also sought to predict the whole deformation process through multistep simulations [20]. A fluid structure interaction simulation for WJISF was performed using a CFD approach.…”