Numerical Study of a Variable Wall Angle Made of DC01 Steel by Incremental Forming Process

Popp, Mihai-Octavian; Rusu, Gabriela-Petruța; Popp, Ilie-Octavian; Gîrjob, Claudia

doi:10.2478/aucts-2022-0004

Cited by 2 publications

(1 citation statement)

References 5 publications

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“…Nevertheless, challenges persist in SPIF, particularly regarding defects in wall thickness uniformity, geometric accuracy, and other process limitations, which impede its broader industrial applications. To address these limitations and enhance SPIF's predictability, a considerable body of research has been dedicated to numerical simulations of the forming process [11][12][13][14][15][16][17].…”

Section: Introductionmentioning

confidence: 99%

Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of Al1050 Sheet Material

Hoang,

Luyen,

Nguyen

2023

Materials

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Single-point incremental forming (SPIF) has emerged as a cost-effective and rapid manufacturing method, especially suitable for small-batch production due to its minimal reliance on molds, swift production, and affordability. Nonetheless, SPIF’s effectiveness is closely tied to the specific characteristics of the employed sheet materials and the intricacies of the desired shapes. Immediate experimentation with SPIF often leads to numerous product defects. Therefore, the pre-emptive use of numerical simulations to predict these defects is of paramount importance. In this study, we focus on the critical role of the forming limit curve (FLC) in SPIF simulations, specifically in anticipating product fractures. To facilitate this, we first construct the forming limit curve for Al1050 sheet material, leveraging the modified maximum force criterion (MMFC). This criterion, well-established in the field, derives FLCs based on the theory of hardening laws in sheet metal yield curves. In conjunction with the MMFC, we introduce a graphical approach that simplifies the prediction of forming limit curves at fracture (FLCF). Within the context of the SPIF method, FLCF is established through both uniaxial tensile deformation (U.T) and simultaneous uniform tensile deformation in bi-axial tensile (B.T). Subsequently, the FLCF predictions are applied in simulations and experiments focused on forming truncated cone parts. Notably, a substantial deviation in fracture height, amounting to 15.97%, is observed between simulated and experimental samples. To enhance FLCF prediction accuracy in SPIF, we propose a novel method based on simulations of truncated cone parts with variable tool radii. A FLCF is then constructed by determining major/minor strains in simulated samples. To ascertain the validity of this enhanced FLCF model, our study includes simulations and tests of truncated cone samples with varying wall angles, revealing a substantial alignment in fracture height between corresponding samples. This research contributes to the advancement of SPIF by enhancing our ability to predict and mitigate product defects, ultimately expanding the applicability of SPIF in diverse industrial contexts.

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Section: Introductionmentioning

confidence: 99%

Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of Al1050 Sheet Material

Hoang,

Luyen,

Nguyen

2023

Materials

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A Combined simulation and experimental investigation on tool radius influence on enhancing the formability SPIF process for Al1050 sheet material

Luyen,

Hoang,

Nguyen

2024

Int. J. Mod. Phys. B

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This research presents a comprehensive investigation into the pioneering domain of single point incremental forming (SPIF), focusing on elucidating the nuanced interplay between tool radius and formability. By employing a combination of rigorous simulation and experimental methodologies, the study sheds light on the pivotal influence of tool radius on forming performance. Various tool radius values spanning from 2 to 7 are systematically tested in conjunction with corresponding forming angles, revealing crucial insights into their synergistic effects. A critical threshold radius (Rt) is discerned, representing the point at which optimal formability is attained. Below this threshold, a decline in formability is observed, attributed to excessive surface cutting and metal pressing phenomena evident in tests utilizing pointed tools. Finite element (FE) analysis corroborates these findings, demonstrating that compression beneath the tool center induces unstable strain, consequently diminishing forming height as tool radius decreases. Conversely, beyond the Rt, an increase in tearing is noted due to reduced compression. This underscores the delicate balance required in selecting an appropriate tool radius to maximize shaping capacity in SPIF processes. Importantly, the research highlights the significance of achieving high compression capacity alongside an optimal tool radius, emphasizing the intricate yet essential factors influencing SPIF’s formability and shaping capabilities. Furthermore, this study contributes to the advancement of SPIF technology by uncovering novel insights into the dynamic relationship between tool geometry and formability, thereby paving the way for enhanced process optimization and design in various manufacturing applications. This research delves into the innovative realm of SPIF by exploring the intricate relationship between tool radius and formability. Through meticulous simulation and experimentation, the study unveils the pivotal role of tool radius in forming performance. The different values of tool radius, ranging from 2 to 7, are coupled with appropriate forming angles. A critical Rt is identified, where optimal formability is achieved. Conversely, below this threshold, formability declines due to excessive surface cutting and metal pressing, observed in tests employing pointed tools. FE analysis substantiates that compression below the tool center triggers unstable strain, diminishing forming height with decreasing tool radius. Notably, above the Rt, an increase in tearing is observed due to decreased compression. In this context, attaining high compression capacity alongside an appropriate tool radius emerges as the key to maximizing shaping capacity in SPIF.

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Numerical Study of a Variable Wall Angle Made of DC01 Steel by Incremental Forming Process

Cited by 2 publications

References 5 publications

Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of Al1050 Sheet Material

Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of Al1050 Sheet Material

A Combined simulation and experimental investigation on tool radius influence on enhancing the formability SPIF process for Al1050 sheet material

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