Simulation and experimental observations of effect of different contact interfaces on the incremental sheet forming process

Li, Yanle, Liu, Zhaobing, Daniel, W. J. T. (Bill) and Meehan, P. A. (2014) Simulation and experimental observations of effect of different contact interfaces on the incremental sheet forming process. Materials and Manufacturing Processes, 29 2: 121-128. doi:10.1080/10426914.2013.822977


Author Li, Yanle
Liu, Zhaobing
Daniel, W. J. T. (Bill)
Meehan, P. A.
Title Simulation and experimental observations of effect of different contact interfaces on the incremental sheet forming process
Journal name Materials and Manufacturing Processes   Check publisher's open access policy
ISSN 1042-6914
1532-2475
Publication date 2014-01-01
Year available 2013
Sub-type Article (original research)
DOI 10.1080/10426914.2013.822977
Open Access Status Not Open Access
Volume 29
Issue 2
Start page 121
End page 128
Total pages 8
Place of publication Philadelphia, PA, United States
Publisher Taylor & Francis
Language eng
Formatted abstract
Incremental sheet forming (ISF) is a promising forming process perfectly suitable for manufacturing customized products with large plastic deformation by using a simple moving tool. Up to now, however, the effects of contact conditions at the sheet interface are not well understood. The aim of this work is to study the effect of tool type and size on the formability and surface integrity during the forming process. Experimental tests were carried out on aluminum sheets of 7075-O to create a straight groove with four different tools (ϕ 30, ϕ 25.4, ϕ 20 and ϕ 10mm). One tool tip was fitted with a roller ball (ϕ 25.4mm) while the other three were sliding tips. The contact force, friction and failure depth were evaluated. A finite element (FE) model of the process was set up in an explicit code LS-DYNA and the strain behavior and thickness distribution with different tools were evaluated and compared with the experimental results. This study provides important insights into the relatively high formability observed in the ISF process. Microscopic observations of the surface topography revealed that a rolling tool tip produced better surface integrity as compared with a sliding tool tip, wherein, distinct scratch patterns in the tool traverse direction were evident.
Keyword Deformation
Forces
Forming
Strain
Stresses
Q-Index Code C1
Q-Index Status Confirmed Code
Institutional Status UQ
Additional Notes Accepted author version posted online: 29 Oct 2013

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 12 times in Thomson Reuters Web of Science Article | Citations
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Created: Wed, 05 Mar 2014, 23:51:07 EST by Alex Fitzgerald on behalf of School of Mechanical and Mining Engineering