Abstract

This paper presents a numerical simulation of the incremental sheet metal forming (ISF) process, type single point incremental forming (SPIF). A finite element model (FEM) is developed by using the commercial FE code ABAQUS. An elasto-plastic constitutive model with quadratic yield criterion of Hill’48 and isotropic hardening behavior has been adopted during ISF operation. A user material subroutine (VUMAT) is used to implement this material behavior. Four strategies of tool path during the ISF of a piece having a square box final shape are presented. Results including thickness variation of sheet metal, forming force along Z -axis and the Hill’48 stress distribution for the four strategies are presented and compared at the aim to optimize the SPIF and to see which tool path strategy makes this process more effective with the consideration of the characteristics of specimen manufactured and its material properties.

Highlights

  • Incremental sheet forming (ISF) is an innovative process to manufacture sheet metal with numeric increments on CNC machines through plastic deformation

  • The present investigation is a contribution of work that started using an incremental sheet metal forming (ISF) process by taking into account the elastoplastic properties with quadratic yield criterion of Hill and isotropic hardening behavior in the model of sheet forming by single point incremental forming (SPIF)

  • Square box application of ISF was investigated and the results carried out with the use of two numerical treatments, the first is based on ABAQUS/Explicit code and the second is based on the user material subroutine (VUMAT)

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Summary

Introduction

Incremental sheet forming (ISF) is an innovative process to manufacture sheet metal with numeric increments on CNC machines through plastic deformation. Finite element analyses, using an implicit method, have been performed by Ben Ayed et al [8] to develop a simplified numerical approach to simulate the ISF with precision and with reduction of CPU time In this contribution, a shell element DKT12 was implemented and coupled with an elasto-plastic model based on a classical flow rule, isotropic hardening has been considered in the simulations. The present investigation is a contribution of work that started using an incremental sheet metal forming (ISF) process by taking into account the elastoplastic properties with quadratic yield criterion of Hill and isotropic hardening behavior in the model of sheet forming by SPIF. A comparison between four tool paths strategies developed by a known CAM software (CATIA V5 R17) is made to see the effect of these strategies on the ISF parameters and which strategy is more effective for the studied specimen

Constitutive model
Integration algorithm
Extension to large deformation elastoplasticity
Results and discussions
Effects of the tool path strategies
Conclusion

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