Finite element modelling and experimental investigation of single point incremental forming process of aluminum sheets: influence of process parameters on punch force monitoring and on mechanical and geometrical quality of parts

Arfa, Henia; Bahloul, Riadh; Belhadjsalah, Hédi

doi:10.1007/s12289-012-1101-z

Cited by 53 publications

(43 citation statements)

References 45 publications

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“…From the numerical simulation standpoint, the SPIF process represents a particular challenge concerning computation time, which tends to be higher than those of conventional processes, both for implicit or explicit analysis. Previous results in the literature show that numerical simulation needs a compromise between accuracy and CPU efficiency related to the temporal integration scheme, material law, finite element formulation and mesh size (Lequesne et al, 2008;Bouffioux et al 2008;Eychens et al, 2009;van den Boogard, 2008 andAerens et al, 2010;Sena et al 2011, Arfa et al, 2012.…”

Section: Figure 1 -Asymmetric Incremental Sheet Forming Variantsmentioning

confidence: 99%

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Sena

Lequesne²,

Duchêne

et al. 2016

Engineering Computations

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Single Point Incremental Forming (SPIF) is a dieless manufacturing process in which a sheet is deformed by using a tool with a spherical tip. This dieless feature makes the process appropriate for rapidprototyping and allows for an innovative possibility to reduce overall costs for small batches, since the process can be performed in a rapid and economic way without expensive tooling. As a consequence, research interest related to SPIF process has been growing over the last years.Numerical simulation of SPIF process can be very demanding and time consuming, mainly due to the the high non-linearity and constantly changing contact conditions between the tool and the sheet surface, as well as the nonlinear material behavior combined with non-monotonic strain paths. To reduce the simulation time, in the present work an adaptive remeshing technique is proposed being implemented in the in-house implicit finite element code LAGAMINE. This remeshing technique automatically refines only a portion of the sheet mesh at the tool's vicinity, therefore following the tool's motion. As a result, uniformly refined meshes required for accuracy purposes are avoided and consequently, the total CPU time can be drastically reduced.In this work, the proposed automatic refinement technique is applied developed within a Reduced Enhanced Solid-Shell (RESS) framework to further improve numerical efficiency. Finally, validations by means of benchmarks are carried out, with comparisons against experimental results. Keywords

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Section: Figure 1 -Asymmetric Incremental Sheet Forming Variantsmentioning

confidence: 99%

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Sena

Lequesne²,

Duchêne

et al. 2016

Engineering Computations

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“…FEA were successfully implemented to analyze stress and strain during the sheet deformation (Shanmuganatan & Senthil Kumar, 2012). Various studies have investigated the parameters like wall angle, tool diameter, incremental step size and material thickness critical in SPIF by the aid of numerical models (Arfa, Bahloul, & BelHadjSalah, 2012;Bahloul, Arfa, & Belhadjsalah, 2013;Shanmuganatan & Senthil Kumar, 2013). FEA are now widely employed for better understanding of the defects occurring in the formed component.…”

Section: Introductionmentioning

confidence: 99%

Parameters for the FEA simulations of single point incremental forming

Gupta

Jeswiet

2019

Production & Manufacturing Research

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Single point incremental forming has shown immense potential in the manufacture of prototypes. The sheet metal deformation in this technique is carried out by a small hemispherical or flat tool that moves from the sheet periphery to the sheet center while also pushing the sheet down. Simulations of single point incremental forming can be a tedious task since the area required to be formed is large and the two sheet contact area is fairly small. The effect of tool however, affects the entire geometry by causing deflections and radial strains. Hence, it becomes essential to understand the effect of certain parameters that influence the simulation results for this forming process. The paper aims to study factors influencing the simulation of single point incremental forming process. It gives a description of techniques employed to simulate non-linear behavior of sheet metal forming along with the implicit and explicit methodology. Information on the selection of element type including Reduced Enhanced Solid-Shell element is presented. Techniques employed to avoid locking are also discussed. ARTICLE HISTORY

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“…The beneficial aspects of ISF are mainly ascribed to the essence of this technique; that is progression of forming process by transmission of localized plastic deformation [3]. However, this characteristic of ISF induces a major imperfection, that is long processing time.…”

Section: Introductionmentioning

confidence: 99%

High-Speed Incremental Forming Process: A Trade-Off Between Formability and Time Efficiency

Khalatbari

Iqbal

Shi

et al. 2015

Materials and Manufacturing Processes

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Making use of ''optimal experimental design,'' the paper attempts to investigate individual and interactive effects of predictor parameters, namely tool size, pitch size, feed rate, spindle rotational speed, and blank thickness, on sheet formability in single point incremental forming (SPIF) process. For the sake of precision, a novel sensor system was developed and employed to detect crack as it initiates on SPIF test specimens. A novel benchmark for formability in SPIF was established by addressing normal strain along sheet thickness, maximum attainable forming angle, and the rate of variation in forming angle. The process was finally optimized in terms of maximum achievable formability and minimum processing time. Accordingly, high-speed forming (with forming speed of at least 5000 mm/min) was realized to be perfectly viable, whereas the sheet formability remains quite satisfactory (over 90% of the maximum value). The key role of high spindle speed (up to 3000 rpm) was also highlighted in this regard.

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Finite element modelling and experimental investigation of single point incremental forming process of aluminum sheets: influence of process parameters on punch force monitoring and on mechanical and geometrical quality of parts

Cited by 53 publications

References 45 publications

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

Parameters for the FEA simulations of single point incremental forming

High-Speed Incremental Forming Process: A Trade-Off Between Formability and Time Efficiency

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