Abstract
Single Point Incremental Forming (SPIF) is an innovative die-less low-cost forming method. Until now, there have not been viable numerical solutions regarding computational time and accuracy for the incremental forming of polymers. Unlike other numerical approaches, this novel work describes a coupled thermomechanical finite element model that simulates the SPIF of polymer sheets, where a simple elastoplastic constitutive equation rules the mechanical behavior. The resulting simulation attains a commitment between time and accuracy in the prediction of forming forces, generated and transmitted heat, as well as final part dimensions. An experimental test with default process parameters was used to determine an adequate numerical configuration (element type, mesh resolution, and material model). Finally, compared to a set of experimental tests with different thermoplastics, the proposed model, which does not consider complex rheological material models, shows a good agreement with an approximation error of less than 11% in the vertical forming force prediction.
Highlights
Single point incremental forming (SPIF) is the most straightforward implementation of the original idea of Leszak [1] for incremental sheet forming (ISF)
This paper describes a thermo-mechanical model for the SPIF of thermoplastic sheets
Demanding than complex rheological models. It worth is worth mentioningthe thediscussion discussion of of the the influence influence of size, It is mentioning of different differentelement elementtypes, types,element element size, material models, andthe thetesting testingofofthree threepolymers: polymers: Polyvinyl Chloride (PVC)
Summary
Single point incremental forming (SPIF) is the most straightforward implementation of the original idea of Leszak [1] for incremental sheet forming (ISF). In a SPIF operation, the movement of a small hemispheric tool, usually Computer Numerical Control (CNC) controlled, deforms a sheet of material, fixed to a rigid frame by a holder, producing a 3D shape (Figure 1). High formability and the low-cost die-less setup required are the SPIF advantages appreciated by the automotive, aerospace, and medical sectors. The SPIF process is slower than conventional forming processes and faced problems of dimensional accuracy, thinning, and surface finishing. It is essential to overcome the drawbacks mentioned above to take advantage of SPIF formability and flexibility. The study of the deformation mechanism and material behavior can help to improve the process
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