Abstract
Focusing on incremental bulk metal forming processes, the indentation process is gaining interest as a fundamental part of these kinds of processes. This paper presents the analysis of the pressure obtained in indentation under the influence of different punch geometries. To this end, an innovative Upper Bound Theorem (UBT) based solution is introduced. This new solution can be easily applied to estimate the necessary force that guarantees plastic deformation by an indentation process. In this work, we propose an accurate analytical approach to analyse indentation under different punches. The new Modular Upper Bound (MUB) method presents a simpler and faster application. Additionally, its complexity is not considerably increased by the addition of more Triangular Rigid Zones. In addition, a two-dimensional indentation model is designed and implemented using the Finite Element Method (FEM). The comparison of the two methods applied to the indentation process analysed—the new Modular Upper Bound technique and the Finite Element Method—reveal close similarities, the new Modular Upper Bound being more computationally efficient.
Highlights
The application of incremental bulk metal forming processes is gaining growing interest in the current industry
The comparison of the two methods applied to the indentation process analysed—the new Modular Upper Bound technique and the Finite Element Method—reveal close similarities, the new Modular Upper Bound being more computationally efficient
This matches with the behaviour of Modular Upper Bound (MUB) for flat punch (FP) (Figure 9B) and previously published trends [20]
Summary
The application of incremental bulk metal forming processes is gaining growing interest in the current industry. It allows forging materials that present high resistance to deformation, obtaining large final shapes Another important issue is the tools simplicity—normally a simple punch—and their exchangeable capability. The high smoothness of the final workpiece deformed by these processes, the material economy and the aptitude for a complete management with Computer Numerical Control (CNC) machines can be noted. To this end, having these processes implemented in the current industry plays an important role in achieving a competitive production
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