Simulation of incremental forming processes of a pyramidal ring made of two materials

Abstract

Incremental forming is one of the most well-known forming processes for complex and asymmetric parts. This method uses a CNC machine, simple forming tool, and a die. This study focused on effects of some parameters such as the material, feed rate, pitch, rotational speed and movement strategy of tool on the dimensional precision, forming force, thickness distribution and fracture in the welding area. The results showed that single point incremental forming (SPIF) led to a better thickness distribution with lower tool force, whereas two-point incremental forming led to better dimensional accuracy. Rotational speed does not have any significant impact on the forming process while decreasing the feed rate partially reduced the forming force. According to the results, although dimensional precision in double point incremental forming is better than SPIF, when it comes to the thickness distribution, forming force, and economic issues, SPIF is in favor. The results also showed that by connecting two materials, different parameters for the two materials could be investigated simultaneously in one simulation process.

Optimization study of single point incremental forming process of low carbon steel/CP-Titanium bimetallic sheets using grey relational analysis and response surface methodology

“…Simulation results for SPIF process depend heavily on the element type selected. In preceding studies, it is noted that the best results could be obtained using four-node shell element (S4R) in, a lower computational time than brick elements [18,[48][49][50]. In fact, the bending effect requires a minimum of three layers across the sheet's thickness using brick elements type, which leads to a huge CPU time.…”