For the sake of reducing the extremely long time-cost in the incremental sheet forming simulation process, a new simulation method combining symmetry setting and mass scaling setting is introduced in this work. In this paper, a CNC milling machine was used to shape a 40◦ pyramid in the material of AA3003-H18 Al alloy sheet at room temperature. Simulations were designed based on the experiment. Mass scaling in different factors 100, 500, 900 for 1/2, 1/4 and whole part symmetrical settings were investigated to reduce the simulation time. Furthermore, mises stress, equivalent strain, thickness, and profile of the part were compared. The results indicate that the 1/4 parts explicit dynamic simulation in mass scaling factor 900 keeps a good consistency with whole part simulation and also greatly reduces simulation time by 94%, which can be used for quick simulation of ISF. Compared with frequently-used methods (like explicit replacing implicit code), the method in this work achieves higher efficiency without losing accuracy. The proposed method provides a new idea to shorten the simulation verification time for researchers, which can greatly shorten the research cycle of ISF.
Reference
T. Trzepiecinski and H. G. Lemu, “Recent developments and trends in the friction testing for conventional sheet metal forming and incremental sheet forming,” Metals, vol. 10, no. 1, pp. 1–34, 2019. doi: https://doi.org/10.3390/met10010047
M. Murugesan et al., “Investigation of single point incremental sheet forming process: Extraction of constitutive models and parameters optimization,” Jeju National University Graduate School, Jeju, South Korea, Phd thesis, 2021.
Z. Cheng, Y. Li, C. Xu, Y. Liu, S. Ghafoor, and F. Li, “Incremental sheet forming towards biomedical implants: A review,” Journal of Materials Research and Technology, vol. 9, no. 4, pp. 7225–7251, 2020. doi: https://doi.org/10.1016/j.jmrt.2020.04.096
A. Kumar, V. Gulati, P. Kumar, and H. Singh, “Forming force in incremental sheet forming: A comparative analysis of the state of the art,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 41, no. 6, pp. 1–45, 2019. doi: https://doi.org/10.1007/s40430-019-1755-2
A. Bouhamed, H. Jrad, L. B. Said, M. Wali, and F. Dammak, “A non-associated anisotropic plasticity model with mixed isotropic-kinematic hardening for finite element simulation of incremental sheet metal forming process,” The International Journal of Advanced Manufacturing Technology, vol. 100, no. 1, pp. 929–940, 2019. doi: https://doi.org/10.1007/s00170-018-2782-3
X. Xiao, C.-I. Kim, X.-D. Lv, T.-S. Hwang, and Y.-S. Kim, “Formability and forming force in incremental sheet forming of aa7075-t6 at different temperatures,” Journal of Mechanical Science and Technology, vol. 33, no. 8, pp. 3795–3802, 2019. doi: https://doi.org/10.1007/s12206-019-0722-2
S. Zhang, G. Tang, Z. Li, X. Jiang, and K. Li, “Experimental investigation on the springback of AZ31B mg alloys in warm incremental sheet forming assisted with oil bath heating,” The International Journal of Advanced Manufacturing Technology, vol. 109, no. 1, pp. 535–551, 2020. doi: https://doi.org/10.1007/s00170-020-05678-z
H. Arfa, R. Bahloul, and H. Belhadjsalah, “Finite element modelling and experimental investigation of single point incremental forming process of aluminum sheets: Influence of process parameters on punch force monitoring and on mechanical and geometrical quality of parts,” International Journal of Material Forming, vol. 6, no. 4, p. 483510, 2013. doi: https://doi.org/10.1007/s12289-012-1101-z
Z. Chang, M. Li, and J. Chen, “Analytical modeling and experimental validation of the forming force in several typical incremental sheet forming processes,” International Journal of Machine Tools and Manufacture, vol. 140, pp. 62–76, 2019. doi: https://doi.org/10.1016/j.ijmachtools.2019.03.003
Z. Liu, “Heat-assisted incremental sheet forming: A tate-of-the-art review,” The International Journal of Advanced Manufacturing Technology, vol. 98, no. 9, pp. 2987–3003, 2018. doi: https://doi.org/10.1007/s00170-018-2470-3
D. Nasulea and G. Oancea, “Integrating a new software tool used for tool path generation in the numerical simulation of incremental forming processes,” Strojniski Vestnik/Journal of Mechanical Engineering, vol. 64, no. 10, pp. 643–651, 2018. doi: https://doi.org/10.5545/sv-jme.2018.5475
S. Dejardin, S. Thibaud, J.-C. Gelin, and G. Michel, “Experimental investigations and numerical analysis for improving knowledge of incremental sheet forming process for sheet metal parts,” Journal of Materials Processing Technology, vol. 210, no. 2, pp. 363–369, 2010. doi: https://doi.org/10.1016/j.jmatprotec.2009.09.025
J. R. Duflou, A.-M. Habraken, J. Cao, R. Malhotra, M. Bambach, D. Adams, H. Vanhove, A. Mohammadi, and J. Jeswiet, “Single point incremental forming: State-of-the-art and prospects,” International Journal of Material Forming, vol. 11, no. 6, pp. 743–773, 2018. doi: https://doi.org/10.1007/s12289-017-1387-y
F. Jam, A. Rauf, I. Husnain, H. Bilal, A. Yasir, and M. Mashood, “Identify factors affecting the management of political behavior among bank staff,” African Journal of Business Management, vol. 5, no. 23, pp. 9896–9904, 2014.
J. Smith, R. Malhotra, W. Liu, and J. Cao, “Deformation mechanics in single-point and accumulative double-sided incremental forming,” The International Journal of Advanced Manufacturing Technology, vol. 69, no. 5, pp. 1185–1201, 2013. doi: https://doi.org/10.1007/s00170-013-5053-3
H. Ren, N. Moser, Z. Zhang, E. Ndip-Agbor, J. Smith, K. F. Ehmann, and J. Cao, “Effects of tool positions in accumulated double-sided incremental forming on part geometry,” Journal of Manufacturing Science and Engineering, vol. 137, no. 5, pp. 1–8, 2015. doi: https://doi.org/10.1115/1.4030528
Q. Qin, E. S. Masuku, A. N. Bramley, A. R. Mileham, and G. W. Owen, “Incremental sheet-metal forming simulation and accuracy,” Verona, Italy: ICTP, Working paper no-484, 2005.
P. Eyckens, A. Van Bael, R. Aerens, J. Duflou, and P. Van Houtte, “Small-scale finite element modelling of the plastic deformation zone in the incremental forming process,” International Journal of Material Forming, vol. 1, no. 1, pp. 1159–1162, 2008. doi: https://doi.org/10.1007/s12289-008-0186-x
M. Sbayti, R. Bahloul, and H. Belhadjsalah, “Efficiency of optimization algorithms on the adjustment of process parameters for geometric accuracy enhancement of denture plate in single point incremental sheet forming,” Neural Computing and Applications, vol. 32, no. 13, pp. 8829–8846, 2020. doi: https://doi.org/10.1007/s00521-019-04354-y
F. A. Jam, S. K. G. Singh, B. Ng, N. Aziz et al., “The interactive effect of uncertainty avoidance cultural values and leadership styles on open service innovation: A look at Malaysian healthcare sector,” International Journal of Business and Administrative Studies, vol. 4, no. 5, pp. 208–223, 2018. doi:https://dx.doi.org/10.20469/ijbas.4.10003-5
N. Ain, K. Kaur, and M. Waheed, “The influence of learning value on learning management system use: An extension of UTAUT2,” Information Development, vol. 32, no. 5, pp. 1306–1321, 2016. doi: https://doi.org/10.1177/0266666915597546
N. A. Norrdin, “Three dimensional cutting force and tool deflection in micro-end milling aisi D2,” University Technology Mara, Shah Alam, Malaysia, Phd thesis, 2016.
Z. Zhuang, The Analysis and Applications of Finite Element Method based on ABAQUS. Beijing, China: Tsinghua University, 2009.
H. Ren, J. Xie, S. Liao, D. Leem, K. Ehmann, and J. Cao, “In-situ springback compensation in incremental sheet forming,” CIRP Annals, vol. 68, no. 1, pp. 317–320, 2019. doi: https://doi.org/10.1016/j.cirp.2019.04.042
Y. Sun, Z. Lu, C. Li, R. Wang, and W. Zhai, “Study on the springback effect and surface property for ultrasonic-assisted incremental sheet forming of aluminum alloy,” Symmetry, vol. 13, no. 7, pp. 1–10, 2021. doi: https://doi.org/10.3390/sym13071217
J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, and J. Allwood, “Asymmetric single point incremental forming of sheet metal,” CIRP Annals, vol. 54, no. 2, pp. 88–114, 2005. doi: https://doi.org/10.1016/S0007-8506(07)60021-3
K. Jackson and J. Allwood, “The mechanics of incremental sheet forming,” Journal of Materials Processing Technology, vol. 209, no. 3, pp.
1158–1174, 2009. doi: https://doi.org/10.1016/j.jmatprotec.2008.03.025
