Forming forces in single point incremental forming: prediction by finite element simulations, validation and sensitivity

Authors:
C. Henrard;C. Bouffioux;P. Eyckens;H. Sol;J. R. Duflou;P. Van Houtte;A. Van Bael;L. Duchêne;A. M. Habraken
Affiliations:
ArGEnCo, Université de Liège, Liège, Belgium 4000 and Samtech S.A., Liège, Belgium 4031;ArGEnCo, Université de Liège, Liège, Belgium 4000;MTM, Katholieke Universiteit Leuven, Heverlee, Belgium 3001;MEMC, Vrije Universiteit Brussel, Brussels, Belgium 1050;PMA, Katholieke Universiteit Leuven, Heverlee, Belgium 3001;MTM, Katholieke Universiteit Leuven, Heverlee, Belgium 3001;MTM, Katholieke Universiteit Leuven, Heverlee, Belgium 3001 and KHLim (Limburg Catholic University College), Diepenbeek, Belgium 3590;ArGEnCo, Université de Liège, Liège, Belgium 4000;ArGEnCo, Université de Liège, Liège, Belgium 4000
Venue:
Computational Mechanics
Year:
2011

Citing 2
Cited 1

Numerical Methods for Unconstrained Optimization and Nonlinear Equations (Classics in Applied Mathematics, 16)

Numerical Methods for Unconstrained Optimization and Nonlinear Equations (Classics in Applied Mathematics, 16)
Contact between deformable solids: The fully coupled approach

Mathematical and Computer Modelling: An International Journal

Off-line compensation of the tool path deviations on robotic machining: Application to incremental sheet forming

Robotics and Computer-Integrated Manufacturing

Quantified Score

Hi-index	0.00

Visualization

Abstract

The aim of this article is to study the accuracy of finite element simulations in predicting the tool force occurring during the single point incremental forming (SPIF) process. The forming of two cones in soft aluminum was studied with two finite element (FE) codes and several constitutive laws (an elastic---plastic law coupled with various hardening models). The parameters of these laws were identified using several combinations of a tensile test, shear tests, and an inverse modeling approach taking into account a test similar to the incremental forming process. Comparisons between measured and predicted force values are performed. This article shows that three factors have an influence on force prediction: the type of finite element, the constitutive law and the identification procedure for the material parameters. In addition, it confirms that a detailed description of the behavior occurring across the thickness of the metal sheet is crucial for an accurate force prediction by FE simulations, even though a simple analytical formula could provide an otherwise acceptable answer.