Force Modeling in Single Point Incremental Forming of Variable Wall Angle Components

Abstract

Prediction of forming forces in Incremental Sheet Forming (ISF) is specially important in the case of using adapted machinery not designed for the process. Moreover, forming force is an important indicator that can be monitored on-line and utilized for real time process control. Besides experimentation, simulations based on the Finite Element Method (FEM) have been utilized as a reliable source of process force data. Nevertheless, the long solution times required to simulate ISF renders difficult its inclusion into a process optimization chain. In consequence, models that predict the forces required to manufacture simple parts have appeared. This work begins with a review of forming force models available for Single Point Incremental Forming (SPIF). Then, an equation recently proposed in the literature is compared with published experimental results of SPIF under different working conditions. The same data is employed to verify our own FEM simulations. Finally, the above-mentioned formula and FEM simulation were applied to predict the forming force of Variable Wall Angle (VWA) geometries where available force information is limited. Besides the applicability assessment of the equation, results will supplement a future experimental campaign focused in modeling geometries of intermediate complexity level by means of Computational Intelligence methods.

Critical analysis of necking and fracture limit strains and forming forces in single-point incremental forming

“…The applicability of Eq. (4) for Variable Wall Angle (VWA) geometries has been validated in previous works of the authors [30,31] for different geometries.…”

Single point incremental forming: An assessment of the progress and technology trends from 2005 to 2015

“…4 shows the typical force variation that is expected during a SPIF operation. This model has been validated by benchmarking experiments done by several researchers [74,75], and also by comparison with finite element simulations as in Eyckens et al [69].…”

Experimental Study on the Overall Spifability of AISI 304 Sheets under Different Bending Conditions

“…The testing blanks had dimensions of 150 x 150 mm, being the effective working area 120 x 120 mm. The geometry used in this work was a conical frustum with circular generatrix (see [8] for more details). The initial diameter of the truncated cone was set to 70 mm, being the initial drawing angle 20º and the generatrix radius 40 mm.…”