Multi-pass deformation design for incremental sheet forming: Analytical modeling, finite element analysis and experimental validation

Liu, Zhaobing, Daniel, William J. T., Li, Yanle, Liu, Sheng and Meehan, Paul A. (2014) Multi-pass deformation design for incremental sheet forming: Analytical modeling, finite element analysis and experimental validation. Journal of Materials Processing Technology, 214 3: 620-634. doi:10.1016/j.jmatprotec.2013.11.010

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Author Liu, Zhaobing
Daniel, William J. T.
Li, Yanle
Liu, Sheng
Meehan, Paul A.
Title Multi-pass deformation design for incremental sheet forming: Analytical modeling, finite element analysis and experimental validation
Journal name Journal of Materials Processing Technology   Check publisher's open access policy
ISSN 0924-0136
1873-4774
Publication date 2014-01-01
Year available 2013
Sub-type Article (original research)
DOI 10.1016/j.jmatprotec.2013.11.010
Volume 214
Issue 3
Start page 620
End page 634
Total pages 15
Place of publication Lausanne, Switzerland
Publisher Elsevier S.A.
Language eng
Subject 1706 Computer Science Applications
2611 Modelling and Simulation
2503 Ceramics and Composites
2506 Metals and Alloys
2209 Industrial and Manufacturing Engineering
Abstract Incremental sheet forming (ISF) is a promising rapid prototyping technology with high potential to shape complex three-dimensional parts. However, a common technical problem encountered in ISF is the non-uniform thickness distribution of formed parts; particularly excessive thinning on severely sloped regions. This may lead to fracture and limit the process formability. Design of multi-stage deformation passes (intermediate shapes or preforms) before the final part, is a desirable and practical way to control the material flow in order to obtain a more uniform thickness distribution and avoid forming failure. In the present paper, a systematic methodology for designing multi-stage deformation passes considering the predicted thickness strains given the design shape is proposed based on the shear deformation and the strain compensation mechanism. In this methodology, two analytical models (M1 and M2) are developed by taking into account; the global average thickness strain and only the material in the final part region used in the forming (M1), and the local weighted average thickness strain and the additional material around the final part region used in the forming (M2), respectively. The feasibility of the proposed design methodology is validated by finite element analysis (FEA) and experimental tests using an Amino ISF machine. The results show that a more uniform thickness strain distribution can be derived using M2. The incurrence of the highest strains can be delayed in the intermediate stages and the flow of material is allowed into the deformed region, thereby allowing a compressive stress state to develop and enabling steeper shapes to be formed. Therefore, the process formability can be enhanced via the optimized design of deformation passes.
Keyword Deformation pass
Finite element analysis
Formability
Incremental sheet forming
Intermediate shape
Q-Index Code C1
Q-Index Status Confirmed Code
Institutional Status UQ

Document type: Journal Article
Sub-type: Article (original research)
Collections: School of Mechanical & Mining Engineering Publications
Official 2014 Collection
 
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Citation counts: TR Web of Science Citation Count  Cited 8 times in Thomson Reuters Web of Science Article | Citations
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