Numerical-Experimental Study Regarding the Single Point Incremental Forming Process

Abstract

The present paper proposes a numerical-experimental comparative study on the single point incremental forming process. A DC04 steel sheet with a thickness of 0.6 mm was used for both the numerical simulation using the finite element method and the experimental research. The type of trajectory used was a spiral trajectory and the finished part obtained was a truncated cone-shaped part. The analysis program used for simulation was Ls-Dyna. The simulations were performed in several variants: with a fixed mesh and with an adaptive mesh, using two different element formulations: 25 (Belytschko-Tsay formulation with thickness stretch) and -16 (fully integrated shell element modified for higher accuracy) and two contact types: automatic surface to surface (ASTS) and forming one way surface to surface (FOSS). The results of the numerical analysis and of the experimental research were focused on determining the major strain, minor strain, thickness reduction and forces at the end of the single point incremental forming process, as well as determining the processing time.

Thermo-Mechanical Numerical Simulation of Friction Stir Rotation-Assisted Single Point Incremental Forming of Commercially Pure Titanium Sheets

“…This conclusion is also reflected in Figure 10. Rosca et al [54] indicated that the in-plane force oscillates between maximum and minimum values, shifted relative to each other, depending on the position of the forming tool. Formisano et al [55] concluded that the oscillations are due to a little variability in the stiffness of the sheet, since during a spiral the distance of the tool from the frame is different and, with it, the mechanical reaction of the sheet [55].…”

Investigation of the Effect of SPIF Parameters on the Thickness of Al 2024 Alloy

“…The results showed that the maximum predication force is (25.9 KN) and the maximum predication thickness reduction is (46 %). In another work, Rosca et al [11] conducted a numerical-experimental study of the single-point incremental forming process. The sheet metal is steel (DC04) with a thickness of 0.6 mm, and the geometry produced is a truncated cone.…”