Finite Element Simulations Of Multi Stage Incremental Forming Process

Abstract

The limitation over the maximum formable wall angle in single stage incremental forming can be overcome by adopting multi stage forming strategy. This paper focuses on some preliminary finite element studies on deformation behavior of EDD steel in multi stage incremental forming in terms of thickness distribution, strains and geometric accuracy. The study has been carried by forming a conical cup with 850wall angle in four stages. Thickness distribution results revels that the sine law cannot predict the thickness with increase in number of stages. The major and minor principal strain history shows that the material is under plane strain condition in stage#1 and is towards bi-axial stretching with increase in number of stages. The simulation results also captured the geometric inaccuracies due to the formation of residual cone in Multi Stage Incremental Forming (MSIF). The finite element simulations can be used successfully to decide the number of stages and geometric accuracy parts in MSIF.