Finite Inelastic Deformations of Three-Dimensional Shells with Applications to Sheet Metal Forming Processes

1992 ◽  
pp. 373-387 ◽  
Author(s):  
J. C. Gelin ◽  
P. Boisse
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional

Modeling and Simulation of Continuous Flexible Roll Forming Process

2013 ◽  
Vol 365-366 ◽  
pp. 549-552
Author(s):  
Zhou Sui ◽  
Zhong Yi Cai ◽  
Ming Zhe Li
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Rigid Bodies ◽  
Roll Forming ◽  
Forming Process ◽  
Flexible Roll Forming ◽  
Flexible Roll ◽  
Roll Forming Process

The continuous flexible roll forming process is a novel sheet metal forming technique for effectively manufacture of three-dimensional surface parts. In this study, two types of finite element (FE) models were developed under the ABAQUS/Explicit environment. The difference of the two models is that the rolls are defined as discrete rigid bodies in model No.1 and are deformable in model No.2. An experiment was carried out using the continuous sheet metal forming setup. The comparison of the numerical computation results with the experimental results shows that the model No.2 can be used for the shape prediction of continuous flexible roll forming process well.

Compensations for Tool Path to Enhance Accuracy During Double Sided Incremental Forming

2015 ◽  
Author(s):  
Rakesh Lingam ◽  
Anirban Bhattacharya ◽  
Javed Asghar ◽  
N. Venkata Reddy
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Three Dimensional ◽  
Geometric Accuracy ◽  
Forming Process ◽  
Incremental Sheet Metal Forming

Incremental Sheet Metal Forming (ISMF) is a flexible sheet metal forming process that enables forming of complex three dimensional components by successive local deformations without using component specific tooling. ISMF is also regarded as die-less manufacturing process and in the absence of part-specific dies, geometric accuracy of formed components is inferior to that of their conventional counterparts. In Single Point Incremental Forming (SPIF), the simplest variant of ISMF, bending near component opening region is unavoidable due to lack of support. The bending in the component opening region can be reduced to a larger extent by another variant of ISMF namely Double Sided Incremental Forming (DSIF) in which a moving tool is used to support the sheet locally at the deformation zone. However the overall geometry of formed components still has unacceptable deviation from the desired geometry. Experimental observation and literature indicates that the supporting tool loses contact with the sheet after forming certain depth. Present work demonstrates a methodology to enhance geometric accuracy of formed components by compensating for tool and sheet deflection due to forming forces. Forming forces necessary to predict compensations are obtained using force equilibrium method along with thickness calculation methodology developed using overlap that occurs during forming (instead of using sine law). Results indicate that there is significant improvement in accuracy of the components produced using compensated tool paths.

Three-dimensional characterization of surfaces for sheet metal forming

Wear ◽  
1998 ◽  
Vol 216 (2) ◽  
pp. 244-250 ◽  
Author(s):  
M. Pfestorf ◽  
U. Engel ◽  
M. Geiger
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional

Continuous Sheet Metal Forming - A Linearly Incremental Forming Method for Manufacturing 3D Surface Parts

2012 ◽  
Vol 486 ◽  
pp. 334-339
Author(s):  
Zhong Yi Cai ◽  
Zhi Qing Hu ◽  
Ying Wu Lan ◽  
Ming Zhe Li
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Sheet Metal Part ◽  
Metal Part ◽  
Forming Process ◽  
Downward Displacement ◽  
Flexible Roll ◽  
Continuous Sheet

In order to manufacture a three dimensional sheet metal part effectively, a continuous sheet metal forming process (CSMF) based on flexible roll bending has been proposed and developed. This paper mainly focuses on the fundamental aspects of the process, the principle of CSMF is introduced and the method to estimate the downward displacement of upper roll based on the desired curvature of the deformed sheet metal is presented. The variation of the upper rolls downward displacement with the desired bend radius is shown in graphically. The smoothness of the CSMF parts was measured and analyzed. In the results, it is shown that a three-dimensional sheet metal part can be formed without defects and the formed surfaces are in good agreement with the target shapes.

scholarly journals A Method for Simultaneous Optimization of Blank Shape and Forming Tool Geometry in Sheet Metal Forming Simulations

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 544
Author(s):  
Bojan Starman ◽  
Gašper Cafuta ◽  
Nikolaj Mole
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Selection ◽  
Three Dimensional ◽  
Simultaneous Optimization ◽  
Tool Geometry ◽  
Forming Process ◽  
Edge Geometry ◽  
Blank Shape

This paper presents a numerical method for simultaneous optimization of blank shape and forming tool geometry in three-dimensional sheet metal forming operations. The proposed iterative procedure enables the manufacturing of sheet metal products with geometry fitting within specific tolerances (surface and edge deviations less than 0.5 or 1.0 mm, respectively) that prescribe the maximum allowable deviation between the simulated and desired geometry. Moreover, the edge geometry of the product is affected by the shape of the blank and by an additional trimming phase after the forming process. The influences of sheet metal thinning, edge geometry, and springback after forming and trimming are considered throughout the blank and tool optimization process. It is demonstrated that the procedure effectively optimizes the tool and blank shape within seven iterations without unexpected convergence oscillations. Finally, the procedure thus developed is experimentally validated on an automobile product with elaborated design and geometry which prone to large springback amounts owning to complex-phase advanced high strength steel material selection.

Finite Element Predictions for a Cold Sheet Metal Forming Process Using Tetrahedral Mini-Elements

2011 ◽  
Author(s):  
Min-Cheol Lee ◽  
Sang-Hyun Sim ◽  
Jae-Gun Eom ◽  
Man-Soo Joun ◽  
Wan-Jin Chung
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Thickness Variation ◽  
Forming Process ◽  
Rigid Plastic ◽  
Element Mesh ◽  
Metal Forming Process

In this paper, finite element prediction of a cold sheet metal forming process is investigated using solid elements. A three-dimensional rigid-plastic finite element method with conventional linear tetrahedral MINI-elements [1, 2] is employed. This technique has traditionally been used for bulk metal forming simulations. Both single- and double-layer finite element mesh systems are studied, with particular attention to their effect on the deformed shape of the workpiece and thickness variation. The procedure is applied to the well-known problem of the NUMISHEET93 international benchmark. The resulting predictions are compared with experimental observations found in the literature, and good agreement is noted.

A new approach for inverse analysis of springback in a sheet-bending process

2008 ◽  
Vol 222 (11) ◽  
pp. 1363-1374 ◽  
Author(s):  
A Behrouzi ◽  
B M Dariani ◽  
M Shakeri
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Three Dimensional ◽  
Die Design ◽  
Element Analysis ◽  
New Approach ◽  
Bending Process ◽  
Process Convergence

In sheet metal-forming processes, the final product can deviate from the target shape as a result of springback. Several approaches have been proposed for analysis of springback and compensating for its error. In this paper, a new approach for springback analysis is presented based on inverse modelling. The springback occurs at the last step of the process and the final geometry of the workpiece can be obtained at the end of direct process modelling. By applying inverse springback analysis, iterative die design becomes possible from the end of the process. Applying bending theory in an inverse algorithm, compensation of springback error is performed in the V-bending process. Convergence of the inverse approach is compared with the direct approach. The inverse springback analysis is developed for three-dimensional analysis of sheet metal forming by applying the explicit—implicit finite element method. Inverse springback modelling of asymmetric and large springback processes is feasible by this new algorithm. The capability and accuracy of this method are investigated for various symmetric and asymmetric processes by comparing results of the method by three-dimensional finite element analysis and V-bending experimental results.

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