On some computational aspects for incremental sheet metal forming simulations

Robert, Camille; Santo, Philippe Dal; Delamézière, Arnaud; Potiron, Alain; Batoz, Jean‐Louis

doi:10.1007/s12289-008-0155-4

Cited by 15 publications

(11 citation statements)

References 8 publications

(7 reference statements)

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“…Researchers claimed that FEM simulation of SPIF process took a huge computational time because of large model and non-linear conditions in the system. With ABAQUS/Explicit solver, there are two approaches that can be applied to decrease the computational time such as mass scaling and time scaling [9][10]. Depending on applications, a proper approach should be considered to have an accurate result.…”

Section: Simulation Proceduresmentioning

confidence: 99%

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Numerical Analysis on Formability of AZ61A Magnesium Alloy by Incremental Forming

Senthil

Gnanavelbabu

2014

Procedia Engineering

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The objective of this paper is to discuss the numerical solution of the formability of AZ61A magnesium alloy. Magnesium alloys are the improving materials with their better mechanical properties. The analysis was performed by using explicit version of ABAQUS Finite Element Modules. For achieving better and more realistic solution Incremental Sheet Forming (ISF) technique was used. In the present investigation, a Single Point Incremental Forming (SPIF) tool containing hemispherical end was used to characterize the formability of AZ61A magnesium alloy sheet. For the simulations the punch and dies were assumed to be rigid bodies. The forming loads and details of formability for AZ61A were obtained using contour plots of stress and strain. From the analysis, the formability of the material has been obtained. Stress, strain developed were also found and the maximum stressed area are noted which helps in determining the failure of the sheet metal during forming operation.

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Section: Simulation Proceduresmentioning

confidence: 99%

“…A large material deformation in this process led to a severe element distortion and entanglement. These can lead to decrease in the size of the stable time increment and accuracy of simulated results [10]. Therefore, the adaptive meshing tool should be used in the simulation of SPIF process to increase meshing quality.…”

Section: Adaptive Meshingmentioning

confidence: 99%

Numerical Analysis on Formability of AZ61A Magnesium Alloy by Incremental Forming

Senthil

Gnanavelbabu

2014

Procedia Engineering

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“…Presented work extracts the CAD data from CATIA version5 R20 and exports them to CAM software which is MasterCAM 2010 to extract the G codes and M codes and transfer them to the CNC milling machine. Some works use technical software in the final results to predict the valid results to show the numerical error and the accuracy of the process [3,11]. On the other hand, numerical error also is designed for CNC milling machining which is different with forming with CNC machine.…”

Section: Introductionmentioning

confidence: 99%

Comparative Study between Programming Systems for Incremental Sheet Forming Process

Moayedfar

Rani

Salehi

et al. 2014

MATEC Web of Conferences

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Abstract. Incremental Sheet Forming (ISF) is a method developed to form a desired surface feature on sheet metals in batch production series. Due to a lack of dedicated programming system to execute, control and monitor the whole ISF, researchers tried to utilize programming systems designed for chip making process to suits for ISF. In this work, experiments were conducted to find suitability and quality of ISF parts produced by using manual CNC part programming. Therefore, ISF was carried out on stainless steel sheets using Computer Numerical Control (CNC) milling machines. Prior to running the experiments, a ball-point shaped tool made of bronze alloy was fabricated due to its superior ability to reduce the amount of friction and improve the surface quality of the stainless steel sheet metal. The experiments also employed the method of forming in negative direction with a blank mould and the tool which helped to shape the desired part quickly. The programming was generated using the MasterCAM software for the CNC milling machine and edited before transferring to the machine. However, the programming for the machine was written manually to show the differences of output date between software programming and manual programming. From the results, best method of programming was found and minimum amount of contact area between tool and sheet metal achieved.

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“…The numerical simulation of this process is time consuming due to the necessity to take into account various non-linearity such as the material behaviour, large strain deformation and the evolution of the toolflange contact. A previous work has showed [4] that, in this process, using the theory of incremental deformation to reduce the time for material behaviour non-linearity (compared with the flow rule theory), give good results but the time benefit is small (approximately 5% for a cylindrical cup benchmark). This is because there are a small numbers of elements in plastic domain at a given time increment.…”

Section: Introductionmentioning

confidence: 99%

Development of a simplified approach of contact for incremental sheet forming

et al. 2010

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This paper deal with a simplified approach for the contact management between the tool and the sheet in incremental sheet metal forming process. The general principle of this approached is to imposed displacement of the nodes in contact with the tool at a given position. After a description of this method, some numerical aspects of this algorithm are investigated. Applied a pressure contact on the elements of the contact zone have few influence of the results (deformed shape and thickness) but reduce the computational time of the simulation. The size of tool displacement is also investigated. Using increments of the tool diameter give a good accuracy of the thickness and of the geometry. Large increments do not affect the predicted geometry, but only the minimal thickness of the forming component is accurate. This new algorithm gives a good reduction of the computational time compared with a standard contact algorithm (from a ratio of 0.75 to 0.18, depending of the increment size).

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On some computational aspects for incremental sheet metal forming simulations

Cited by 15 publications

References 8 publications

Numerical Analysis on Formability of AZ61A Magnesium Alloy by Incremental Forming

Numerical Analysis on Formability of AZ61A Magnesium Alloy by Incremental Forming

Comparative Study between Programming Systems for Incremental Sheet Forming Process

Development of a simplified approach of contact for incremental sheet forming

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