Abstract
Incremental sheet metal forming is a die-less process known for its high flexibility, making it a suitable choice for fabricating low-batch, highly customized complex parts. In this paper, the deformation mechanism of double-sided incremental forming (DSIF) with single pass or reforming toolpaths and its effect on the deformation-induced martensite transformation kinetics are investigated by experiments and finite element (FE) simulations for a truncated pyramid part geometry for the first time. An FE model accounting for tool deflection is developed, considering the change in tools' position caused by the forces applied at the contact with the blank. This is done to enhance the simulation accuracy in comparison to experimental results. A comprehensive analysis is conducted with respect to the stress state change and strain accumulation during DSIF with the single pass and reforming toolpaths. The findings reveal that material points along the pyramid wall primarily deform by a combination of plane strain tension, plane strain compression, and shear, depending on the tools’ locations on the sheet surfaces in relation to the material point of interest. The reversal of the forming direction in the reforming toolpath causes material points to experience different stress states and more strain accumulation than the single pass case. Under the same forming temperature, this phenomenon results in a higher and closer martensite transformation on both forming and supporting surfaces of the final part when employing the reforming toolpath as opposed to the single pass case.
Published Version
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