On a Simplified Model for the Tool and the Sheet Contact Conditions for the SPIF Process Simulation

Robert, Camille; Ayed, Lanouar Ben; Delamézière, Arnaud; Santo, Phillippe dal; Batoz, Jean-Louis

doi:10.4028/www.scientific.net/kem.410-411.373

Cited by 6 publications

(5 citation statements)

References 6 publications

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“…This algorithm was tested through the commercial code Abaqus and satisfactory results have been obtained by Robert et al [28]. The goal is to simplify the management of the contact between the tool and the sheet which leads to a reduction of the CPU time.…”

Section: Contact Assumption and Tool Path Control Parametermentioning

confidence: 98%

Simplified numerical approach for incremental sheet metal forming process

Ayed¹,

Robert²,

Delamézière³

et al. 2014

Engineering Structures

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. a b s t r a c tThe current work presents a finite element approach for numerical simulation of the incremental sheet metal forming (ISF) process, called here ''ISF-SAM'' (for ISF-Simplified Analysis Modelling). The main goal of the study is to develop a simplified FE model sufficiently accurate to simulate the ISF process and quite efficient in terms of CPU time. Some assumptions have been adopted regarding the constitutive strains/ stresses equations and the tool/sheet contact conditions. A simplified contact procedure was proposed to predict nodes in contact with the tool and to estimate their imposed displacements. A Discrete Kirchhoff Triangle shell element called DKT12, taking into account membrane and bending effects, has been used to mesh the sheet. An elasto-plastic constitutive model with isotropic hardening behaviour and a static scheme have been adopted to solve the nonlinear equilibrium equations. Satisfactory results have been obtained on two applications and a good correlation has been shown compared to experimental and numerical results, and at the same time a reduction of CPU time more than 60% has been observed. The bending phenomenon studied through the second application and the obtained results show the reliability of the DKT12 element.

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Section: Contact Assumption and Tool Path Control Parametermentioning

confidence: 98%

Simplified numerical approach for incremental sheet metal forming process

Ayed¹,

Robert²,

Delamézière³

et al. 2014

Engineering Structures

Self Cite

View full text Add to dashboard Cite

show abstract

“…Because the majority of deformation in SPIF occurs in a small region around the tool, it is useful to understand the size and shape of this contact area. Contact geometry is useful for modelling aspects such as contact force distributions, 2 material distribution and failure prediction 3 and tribological conditions. While the actual area of contact is not directly needed for these purposes, it is nonetheless useful to have an understanding of the geometry of the contact patch and the influence from parameters such as tool diameter, stepdown and wall angle.…”

Section: In 2005mentioning

confidence: 99%

A new model for contact geometry in single-point incremental forming

Adams

Jeswiet

2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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Because the deformation within single-point incremental forming occurs in a small region around the area of contact, understanding the size and shape of the contact patch is useful to model process conditions. The following presents a new model of contact geometry, wherein contact geometry is derived from the intersection of the tool with the regions that have already been formed. Because this method allows for contact geometry to be determined based on measurable surrounding features, experimental measurements of contact geometry are performed to quantify the contributions of tool diameter, step size and wall angle on contact area.

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“…They reported a shortening of CPU time while still maintaining a sufficient level of accuracy. Later, Robert et al [ 26 ] developed a simplified model for the forming tool/blank contact conditions incorporated into the ABAQUS software. The new algorithm enabled shortening of the computational time by 65% compared to a standard contact algorithm.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

et al. 2022

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Single point incremental forming (SPIF) is one of the most promising technologies for the manufacturing of sheet metal prototypes and parts in small quantities. Similar to other forming processes, the design of the SPIF process is a demanding task. Nowadays, the design process is usually performed using numerical simulations and virtual models. The modelling of the SPIF process faces several challenges, including extremely long computational times caused by long tool paths and the complexity of the problem. Path determination is also a demanding task. This paper presents a finite element (FE) analysis of an incrementally formed truncated pyramid compared to experimental validation. Focus was placed on a possible simplification of the FE process modelling and its impact on the reliability of the results obtained, especially on the geometric accuracy of the part and bottom pillowing effect. The FE modelling of SPIF process was performed with the software ABAQUS, while the experiment was performed on a conventional milling machine. Low-carbon steel DC04 was used. The results confirm that by implementing mass scaling and/or time scaling, the required calculation time can be significantly reduced without substantially affecting the pillowing accuracy. An innovative artificial neural network (ANN) approach was selected to find the optimal values of mesh size and mass scaling in term of minimal bottom pillowing error. However, care should be taken when increasing the element size, as it has a significant impact on the pillow effect at the bottom of the formed part. In the range of selected mass scaling and element size, the smallest geometrical error regarding the experimental part was obtained by mass scaling of 19.01 and tool velocity of 16.49 m/s at the mesh size of 1 × 1 mm. The obtained results enable significant reduction of the computational time and can be applied in the future for other incrementally formed shapes as well.

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On a Simplified Model for the Tool and the Sheet Contact Conditions for the SPIF Process Simulation

Cited by 6 publications

References 6 publications

Simplified numerical approach for incremental sheet metal forming process

Simplified numerical approach for incremental sheet metal forming process

A new model for contact geometry in single-point incremental forming

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

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