Abstract
Single point incremental forming, SPIF, is a forming process that hasa great potential application in sheet metal industries. SPIF is capableof producing medium size batches of complex shapes with low costas it requires no die. This study explores the potentials of integratingcomputer aided manufacturing, CAM, and finite element analysis, FEA,to obtain a virtual model that realistically simulates the SPIF process.The simulation of SPIF process has been carried out using LS-Dyna4.3©software while producing a circular and rectangular taper pockets ona blank made of AL6061. The tool path has been generated using aCAM software and imported to a CNC machine to execute the SPIFprocess, taking into consideration the main forming parameters: thefeed rate and the incremental step size. The results of both simulationand experiment are presented against each other in terms of thicknessreduction, spring back, and cross-sectional profile, and they are provedto be close within an accepted range. The virtual model obtained in thisthe study is believed to be useful for performing an optimization analysisto decide the optimum forming parameters that are thought to affect theSPIF process.
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