Abstract
Friction stir-assisted incremental sheet forming with synchronous bonding is developed as a novel variant of incremental sheet forming, by which the two sheet metals form incrementally and get bonded simultaneously. Numerical simulation of this process is crucial in revealing the forming mechanism and optimizing the process compared with expensive physical tryouts. A coupled thermo-mechanical finite element model was established to take the contact and heat transformation in every interface into consideration, and VUINTER contact subroutine which can express the heat partition coefficient and coefficient of friction was complied, validated and revised by groove tests. The effectiveness of the numerical simulation was verified by experiments. Furthermore, a comparative study based on numerical simulation is conducted to analyze the effects of process variables including feed rate, spindle speed, wall angle and vertical step size on temperature, thickness, and central bulge.
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