An approximate deformation analysis and FEM analysis for the incremental bulging of sheet metal using a spherical roller

Iseki, Hideo

doi:10.1016/s0924-0136(01)00500-3

Cited by 125 publications

(83 citation statements)

References 2 publications

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“…A good conformance between calculations and measurements was achieved for areas that have a shallow curvature. Good qualitative agreement with experimental results were also obtained by Iseki [60]. However, considerable deviations occurred for areas with bending or necking deformation as reported by Young and Jeswiet [61].…”

Section: The Sine Lawsupporting

confidence: 86%

“…To overcome the above computational challenges of the FE approach, Iseki [60] derived the forming force for the incremental forming of a pyramid using a simple approximated deformation analysis based on a plane-strain deformation. The proposed numerical model allowed a systematic investigation of the effects of process parameters on the forming force and thickness distribution.…”

Section: Prediction Of Forming Forcesmentioning

confidence: 99%

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Forming force prediction and process investigation for incremental sheet forming

Li¹

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Incremental sheet forming (ISF) is a promising manufacturing process in which flat metal sheets are gradually formed into 3D shapes using a generic forming tool. Since the process features benefits of reduced forming forces, enhanced formability and greater process flexibility, it has a great potential to achieve economic payoff for rapid prototyping applications and for small quantity production in various applications. Although substantial research has been performed in the past decades on ISF, there is still a lack of an efficient prediction of forming force to facilitate the production design and optimization of the process. Also, unsatisfactory part quality obtained still hampers its wide use in industrial applications. Therefore, the work presented in this thesis is mainly focused on two aspects of ISF: efficient forming force prediction and process investigation and its improvement.The first research aspect of this thesis has been focused on the development of an efficient force prediction model that includes the development of both finite element (FE) and analytical models. (i) FE modelling. Two types of FE models have been established using an explicit code LS-DYNA to investigate the deformation mechanism in ISF which is the basis for developing the force prediction model as well as further improving the forming process. First, FE models with shell elements for the groove forming process were set up and the strain behaviour and thickness distribution with different tools were evaluated and compared with experimental results. The strain behaviour of elements at different positions has been studied and the maximum strain has been found near the end of the groove corresponding to the failure location. The thickness distributions of the groove formed with different sized tools were predicted and it was found that the groove formed by the 20 mm tool is thinner than that formed by the 30 mm tool. Second, to further investigate different deformation modes and their evolution history in ISF, a FE model with fine solid elements for the cone-forming process has been established. The FE model was verified by experimental work with forming forces to allow a quantitative study of deformation behaviours of stretching, bending and shearing during the process. The evolution history of all the strain components along with the effective strain was presented. Moreover, the characteristic of each strain component and its contribution to the total effective plastic strain during the cone-forming process were investigated in detail. It was confirmed from FE simulations that the deformation mechanism in the ISF process is a combination of shearing, bending and stretching though the quantitative contributions in two directions are varied. (ii) Force prediction modelling and its validation. Based on the understanding of the deformation mechanism during the forming process, an efficient analytical model for tangential force prediction has been developed. Initially, deformation modes including shear, bending and stretchin...

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Section: The Sine Lawsupporting

confidence: 86%

Section: Prediction Of Forming Forcesmentioning

confidence: 99%

Forming force prediction and process investigation for incremental sheet forming

Li¹

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“…Usually are used dedicates FEM softwares like Abaqus, LSDyna and Ansys. The main topics studied using FEM simulation are forces analisys [60], springback amplitude and toolpath correction [61], deformation analisys [62], influence of the tool parameter and tool path on the deformation behaviour [30] and so on.…”

Section: Fem Simulation In Isfmentioning

confidence: 99%

Incremental deformation: A literature review

Nasulea

Oancea

2017

MATEC Web Conf.

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Abstract. Nowadays the customer requirements are in permanent changing and according with them the tendencies in the modern industry is to implement flexible manufacturing processes. In the last decades, metal forming gained attention of the researchers and considerable changes has occurred. Because for a small number of parts, the conventional metal forming processes are expensive and time-consuming in terms of designing and manufacturing preparation, the manufacturers and researchers became interested in flexible processes. One of the most investigated flexible processes in metal forming is incremental sheet forming (ISF). ISF is an advanced flexible manufacturing process which allows to manufacture complex 3D products without expensive dedicated tools. In most of the cases it is needed for an ISF process the following: a simple tool, a fixing device for sheet metal blank and a universal CNC machine. Using this process it can be manufactured axis-symmetric parts, usually using a CNC lathe but also complex asymmetrical parts using CNC milling machines, robots or dedicated equipment. This paper aim to present the current status of incremental sheet forming technologies in terms of process parameters and their influences, wall thickness distribution, springback effect, formability, surface quality and the current main research directions.

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“…For sake of simplicity, it has been closely followed the approach of Iseki (2001), which refers to a planar state of deformation. This approximation can be rather well satisfied in case of spherical rollers, with good lubrication and relatively small curvature paths.…”

Section: Analysis Of the Forming Processmentioning

confidence: 99%