Influences of Process Parameters on Forming Performance of Sheet Metal Incremental Forming Based on Numerical Simulation

Abstract

In order to investigate the process of ISF through numerical and experimental approaches, finite element method (FEM) models for two truncated pyramids were developed to simulate the process and the simulated thickness distributions were compared with experimental results. The influences of process parameters on equivalent plastic strain, the maximum equivalent plastic stress and forming force were also discussed. The results show that ISF process is basically to be a plane strain deformation. Wall angle is a more significant influence factor of forming performance than tool diameter and depth increment. With increasing tool diameter, decreasing wall angle and step increment, uniform thickness distribution will be achieved. However, more wall angel, less tool diameter and depth increment contributes to decrease forming force. Additionally, process parameters have no connection with work hardening for a certain material during ISF.