Abstract
In the last two decades, the advances of using computers in sheet metal forming processes have introduced a novel adjustable process known as incremental sheet forming (ISF) as an optimal method for fast prototyping and low numbers of production. Formability and deformation behavior of ISF process are highly affected by the selected process parameters, such as the toolpath, step size, tool diameter, feed rate, and lubrication. The purpose of this work was to study the effect of these process parameters as well as hardening law on single point incremental forming (SPIF) process. For this work, a truncated-cone geometry was considered as a target shape with 7075-O aluminum alloy sheets. The simulations were conducted with different process parameters, i.e., toolpath type, step size, tool size, feed rate, friction coefficient, and wall angle with respect to the tool force and moment, effective plastic strain distribution and thickness of the part. In addition, three types of hardening laws i.e., isotropic extended Voce type hardening law, combined isotropic-kinematic Chaboche type hardening laws with single and double back-stress terms were applied in the finite element simulation of SPIF process. A detailed comparison of these hardening laws' predictions was made with respect to the tool force and moment, effective plastic strain distribution and thickness of the part.
Highlights
Recent advances of using computers in sheet metal forming processes have led to novel adjustable forming techniques evolved from conventional processes like stamping
In a study by Doflou et al on single point incremental forming (SPIF) process, it was reported that a linear fit provides accurate approximations for the forces in different step sizes and tool sizes
The purpose of this study was to investigate the effect of process parameters and different types of hardening models on SPIF process
Summary
Recent advances of using computers in sheet metal forming processes have led to novel adjustable forming techniques evolved from conventional processes like stamping. In a study by Doflou et al on SPIF process, it was reported that a linear fit provides accurate approximations for the forces in different step sizes and tool sizes They provided quadratic fits of the force trends for different sheet thicknesses and wall angles [26]. The purpose of this study was to investigate the effect of process parameters and different types of hardening models on SPIF process For this reason, in the SPIF simulation of 7075-O aluminum alloy sheet, the impact of toolpath type, tool size, step size, feed rate, friction coefficient, and wall angle were studied with respect to the tool force and moment, effective plastic strain distribution and thickness of the part.
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