Three-dimensional finite element method simulation of sheet metal single-point incremental forming and the deformation pattern analysis

Ma, Liang; Mo, Jian Hua

doi:10.1243/09544054jem957

Cited by 21 publications

(6 citation statements)

References 11 publications

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“…The effect of tool path on deformation behaviour was discovered, which shows that the starting forming position should be at one of the corners of the final product. Ma and Mo [18] found that the FE model based on solid elements is more suitable to simulate the SPIF in terms of deformation prediction. Dejardin et al [19] conducted a numerical analysis using LS-DYNA software to predict the springback effect through the cut ring method.…”

Section: Introductionmentioning

confidence: 99%

Deformation analysis in single-point incremental forming through finite element simulation

Daniel

Meehan

2016

Int J Adv Manuf Technol

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Incremental sheet forming (ISF) is a promising manufacturing technology in which complex 3D shapes can be formed with one simple tool. Compared to conventional forming processes, for complex shapes, it is more flexible and economical with higher formability and shorter lead time. Therefore, ISF is ideally suitable to rapid prototype and small-batch production, especially in the aerospace and biomedical sectors. Over the last decade, although the process has been experimentally studied extensively, the associated deformation mechanics is still unclear and intensive investigation is needed. The purpose of this study is to provide further knowledge of the deformation mechanics of the sheet and clarify the deformation mechanism in a typical cone-forming process through finite element (FE) simulation approach. In particular, comprehensive FE models with fine solid elements are utilised, which allow the investigation of deformation modes including stretching, bending and shearing. The FE model is firstly validated with experimental results in terms of forming forces, and then, the evolution history of all the strain components along with the effective strain is presented. The contribution of each strain component to the effective plastic strain during the cone-forming process is discussed. Moreover, the characteristic of each strain component is investigated in detail. It is confirmed from the FE simulation that the deformation modes in the ISF process are a combination of shearing, bending and stretching, although the quantitative contributions in each direction are varied. The effect of step-down size on material plastic deformation as well as formability is also investigated.

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Section: Introductionmentioning

confidence: 99%

Deformation analysis in single-point incremental forming through finite element simulation

Daniel

Meehan

2016

Int J Adv Manuf Technol

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“…However, for the SPIF process, since predicted strain histories were very similar for different yield functions [22,23], von Mises yield criterion was used instead in this study due to its simplicity and a lower computational time. In the simulation of the SPIF process, using solid elements to account for full 3D stress components are more appropriate than using shell type elements [1,31]. To model the blank sheet, 87,773 reduced integration 8-node brick solid elements (C3D8R) with 0.7 mm Â 0.7 mm Â 0.5333 mm (through-thickness) dimensions were used in ABAQUS utilizing 24 CPU processors, E5-2630, with 2.3GHz speed.…”

Section: Fe Simulation Of Spif Process 31 Fem Base Conditionsmentioning

confidence: 99%

Effect of hardening law and process parameters on finite element simulation of single point incremental forming (SPIF) of 7075 aluminum alloy sheet

Esmaeilpour¹,

Kim²,

Park³

et al. 2020

Mechanics & Industry

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In the last two decades, the advances of using computers in sheet metal forming processes have introduced a novel adjustable process known as incremental sheet forming (ISF) as an optimal method for fast prototyping and low numbers of production. Formability and deformation behavior of ISF process are highly affected by the selected process parameters, such as the toolpath, step size, tool diameter, feed rate, and lubrication. The purpose of this work was to study the effect of these process parameters as well as hardening law on single point incremental forming (SPIF) process. For this work, a truncated-cone geometry was considered as a target shape with 7075-O aluminum alloy sheets. The simulations were conducted with different process parameters, i.e., toolpath type, step size, tool size, feed rate, friction coefficient, and wall angle with respect to the tool force and moment, effective plastic strain distribution and thickness of the part. In addition, three types of hardening laws i.e., isotropic extended Voce type hardening law, combined isotropic-kinematic Chaboche type hardening laws with single and double back-stress terms were applied in the finite element simulation of SPIF process. A detailed comparison of these hardening laws' predictions was made with respect to the tool force and moment, effective plastic strain distribution and thickness of the part.

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“…Highly achievable strains and flexible manufacturing methods make the hot incremental sheet forming (HISF) an alternative process to hot forming of titanium alloy sheets. 6–9 Hot stretch bending (HSB) was proposed for bending forming of elongated metal parts. In the HSB process, creep forming is induced after the workpiece was wrapped against the die by maintaining the position of jaw for a selected dwell time.…”

Section: Introductionmentioning

confidence: 99%

Material characterization, constitutive modeling and validation in hot stretch bending of Ti–6Al–4V profile

Deng

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part B:

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Ti–6Al–4V, as one of the most frequently used titanium alloy in aerospace applications, is characterized by its excellent mechanical and corrosion properties. However, it is well known that Ti–6Al–4V is difficult to be formed at room temperature. Therefore, hot stretch bending has been used to improve formability and reduce springback in forming Ti–6Al–4V profile. In the virtual development of designing suitable hot stretch bending processes for Ti–6Al–4V, numerical simulations are considered desirable. However, the reliability of numerical simulations depends on the models and methods used as well as the accuracy of material data. In this work, a set of uniaxial tension tests was performed on Ti–6Al–4V at the temperatures ranging from 923 to 1023 K and strain rate from 0.005 to 0.05 s−1. Moreover, a set of stress relaxation tests was conducted on Ti–6Al–4V at the temperature range between 773 and 973 K and pre-stretch elongation ranging from 0.7% to 10%. The Johnson–Cook and Arrhenius models were used to characterize the uniaxial tension and the stress relaxation behavior, respectively. Finite element model of hot stretch bending was created according to the laboratorial experiment setup in ABAQUS based on the constitutive models calculated above. The finite element simulation indicates that the residual stress in the profile decreases greatly in the secondary stage of hot stretch bending due to the stress relaxation behavior. The predicted springback shows promising agreement with the corresponding experimental observations.

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Three-dimensional finite element method simulation of sheet metal single-point incremental forming and the deformation pattern analysis

Cited by 21 publications

References 11 publications

Deformation analysis in single-point incremental forming through finite element simulation

Deformation analysis in single-point incremental forming through finite element simulation

Effect of hardening law and process parameters on finite element simulation of single point incremental forming (SPIF) of 7075 aluminum alloy sheet

Material characterization, constitutive modeling and validation in hot stretch bending of Ti–6Al–4V profile

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