Title: Finite element analysis of incrementally formed parts

Authors: J.I.V. Sena; R.A.F. Valente; J.J. Grácio; F.J.P. Simões; R.J. Alves de Sousa

Addresses: Department of Mechanical Engineering, TEMA – Centre for Mechanical Technology and Automation, Campus Universitário de Santiago – University of Aveiro, 3810 Aveiro, Portugal. ' Department of Mechanical Engineering, TEMA – Centre for Mechanical Technology and Automation, Campus Universitário de Santiago – University of Aveiro, 3810 Aveiro, Portugal. ' Department of Mechanical Engineering, TEMA – Centre for Mechanical Technology and Automation, Campus Universitário de Santiago – University of Aveiro, 3810 Aveiro, Portugal. ' IPL – Polytechnic Institute of Leiria, Campus 2, Morro do Lena – Alto Vieiro, 2411-901 Leiria, Portugal. ' Department of Mechanical Engineering, TEMA – Centre for Mechanical Technology and Automation, Campus Universitário de Santiago – University of Aveiro, 3810 Aveiro, Portugal

Abstract: Single point incremental forming (SPIF) processes represent a breakpoint from traditional forming processes, and possibly a new era in small batches production, customised parts or rapid prototyping. Given its easy implementation, SPIF is being currently a subject of intensive experimental and numerical research. Consequently, dimensional inaccuracy in formed parts is still a real problem to tackle, demanding a correct prediction of forming forces, springback defects and strain path effects. This work concerns a first step of a detailed numerical study, validated with available experimental results in the literature raised about simulation of SPIF processes. To this end, it is proposed a general simulation framework of SPIF processes using the finite element method with implicit solution schemes, along with innovative solid-shell elements for 3D analysis. Finally, the use of solid-shell elements provides several advantages compared to shell elements, as considering automatically full 3D stress states and constitutive laws, thickness variations, double sided contact and normal stresses.

Keywords: single point incremental forming; SPIF; solid finite elements; line test; implicit analysis; finite element analysis; FEA; simulation; stress states; constitutive laws; thickness variations; double sided contact; normal stresses.

DOI: 10.1504/IJMMS.2011.043082

International Journal of Mechatronics and Manufacturing Systems, 2011 Vol.4 No.5, pp.454 - 469

Published online: 07 Mar 2015 *

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