Comparison of 3D yield functions for finite element simulation of single point incremental forming (SPIF) of aluminum 7075

2017 ◽  
Vol 133 ◽  
pp. 544-554 ◽  
Author(s):  
Rasoul Esmaeilpour ◽  
Hyunki Kim ◽  
Taejoon Park ◽  
Farhang Pourboghrat ◽  
Bassam Mohammed
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Element Simulation ◽  
Yield Functions ◽  
Aluminum 7075

Finite Element Simulation of Ultrasonic Incremental Forming

2016 ◽  
Vol 836-837 ◽  
pp. 452-461
Author(s):  
P.Y. Li ◽  
Qiang Liu ◽  
Wu Run An ◽  
Shu Juan Li
Keyword(s):  
Finite Element ◽  
Sheet Metal ◽  
Axial Force ◽  
Vibration Frequency ◽  
Incremental Forming ◽  
Single Point ◽  
Element Model ◽  
Single Point Incremental Forming ◽  
Element Simulation ◽  
Law Of Cosines

This paper briefly describes the principle of the ultrasonic single point incremental forming of the sheet metal. In which we established the finite element model and finished the finite simulation with ABAQUS. According to the simulation result, we analyzed the influence law of vibration frequency of the axis on the distribution of the stress and strain of the sheet metal, the thickness, and the axial force in the process of ultrasonic single point incremental forming of the sheet metal. The result shows that the influence on the stress and thickness of the sheet metal is minimal, and the influence on the strain follows the law of cosines in which the strain is minimum when the vibration frequency is equal to 15kHZ.The influence on the axial force is that when the frequency is f=0kHz～40kHz the axial force decreases with the increase of the frequency. However, the axial force increased dramatically with the increase of the frequency when the frequency is above 40kHz.

scholarly journals A recommendation of computation of normal streeses in single point incremental forming technology

2014 ◽  
Vol 17 (1) ◽  
pp. 21-28
Author(s):  
Dien Khanh Le ◽  
Nam Thanh Nguyen ◽  
Binh Thien Nguyen
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Incremental Forming ◽  
Single Point ◽  
Finite Element Method Simulation ◽  
Recent Decade ◽  
Work Piece ◽  
Single Point Incremental Forming ◽  
Forming Technology ◽  
Element Method

Single Point Incremental Forming (SPIF) has become popular for metal sheet forming technology in industry in many advanced countries. In the recent decade, there were lots of related studies that have concentrated on this new technology by Finite Element Method as well as by empirical practice. There have had very rare studies by pure analytical theory and almost all these researches were based on the formula of ISEKI. However, we consider that this formula does not reflect yet the mechanics of destruction of the sheet work piece as well as the behavior of the sheet in reality. The main aim of this paper is to examine ISEKI’s formula and to suggest a new analytical computation of three elements of stresses at any random point on the sheet work piece. The suggested formula is carefully verified by the results of Finite Element Method simulation.

The Study on Airborne Equipments Life Prediction Based on the Finite Element Simulation under Comprehensive Stress

2013 ◽  
Vol 365-366 ◽  
pp. 224-228
Author(s):  
Tian Ma ◽  
Chuan Ri Li ◽  
Shuang Long Rong
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Life Prediction ◽  
Single Point ◽  
Simulation Method ◽  
Distribution Fitting ◽  
Kinetic Experiment ◽  
Element Simulation ◽  
Vibration Stress ◽  
Equipment Lifetime

To predict an airborne equipment lifetime with finite element simulation method, use ANSYS and Flothem, respectively, to analysis vibration stress and temperature stress, corrected by kinetic experiment; then import the results into the failure prediction software-CALCE PWA, set the intensity and duration of stress according to its mission profile, finally get the component failure life prediction results under comprehensive temperature and vibration stress; extract the Monte-Carlo simulation data, use the single point of failure distribution fitting, fault clustering and multipoint distribution fusion method to get the board and the whole machines lifetime and reliability prediction. The design refinement suggestion of the airborne equipment is given at the end of the conclusion.

scholarly journals Single point incremental forming simulation with adaptive remeshing technique using solid-shell elements

2016 ◽  
Vol 33 (5) ◽  
pp. 1388-1421 ◽  
Author(s):  
José I.V. Sena ◽  
Cedric Lequesne ◽  
L Duchene ◽  
Anne-Marie Habraken ◽  
Robertt A.F. Valente ◽  
...  
Keyword(s):  
Finite Element ◽  
Incremental Forming ◽  
Single Point ◽  
Nonlinear Material ◽  
Single Point Incremental Forming ◽  
Solid Shell ◽  
Contact Conditions ◽  
Adaptive Remeshing ◽  
Content Type ◽  
Shell Elements

Purpose – Numerical simulation of the single point incremental forming (SPIF) processes can be very demanding and time consuming due to the constantly changing contact conditions between the tool and the sheet surface, as well as the nonlinear material behaviour combined with non-monotonic strain paths. The purpose of this paper is to propose an adaptive remeshing technique implemented in the in-house implicit finite element code LAGAMINE, to reduce the simulation time. This remeshing technique automatically refines only a portion of the sheet mesh in vicinity of the tool, therefore following the tool motion. As a result, refined meshes are avoided and consequently the total CPU time can be drastically reduced. Design/methodology/approach – SPIF is a dieless manufacturing process in which a sheet is deformed by using a tool with a spherical tip. This dieless feature makes the process appropriate for rapid-prototyping and allows for an innovative possibility to reduce overall costs for small batches, since the process can be performed in a rapid and economic way without expensive tooling. As a consequence, research interest related to SPIF process has been growing over the last years. Findings – In this work, the proposed automatic refinement technique is applied within a reduced enhanced solid-shell framework to further improve numerical efficiency. In this sense, the use of a hexahedral finite element allows the possibility to use general 3D constitutive laws. Additionally, a direct consideration of thickness variations, double-sided contact conditions and evaluation of all components of the stress field are available with solid-shell and not with shell elements. Additionally, validations by means of benchmarks are carried out, with comparisons against experimental results. Originality/value – It is worth noting that no previous work has been carried out using remeshing strategies combined with hexahedral elements in order to improve the computational efficiency resorting to an implicit scheme, which makes this work innovative. Finally, it has been shown that it is possible to perform accurate and efficient finite element simulations of SPIF process, resorting to implicit analysis and continuum elements. This is definitively a step-forward on the state-of-art in this field.

scholarly journals Multistage Tool Path Optimisation of Single-Point Incremental Forming Process

Materials ◽  
2021 ◽  
Vol 14 (22) ◽  
pp. 6794
Author(s):  
Zhou Yan ◽  
Hany Hassanin ◽  
Mahmoud Ahmed El-Sayed ◽  
Hossam Mohamed Eldessouky ◽  
Joy Rizki Pangestu Djuansjah ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Processing Time ◽  
Incremental Forming ◽  
Single Point ◽  
Computational Time ◽  
Single Point Incremental Forming ◽  
Two Stage ◽  
Element Analysis ◽  
Wide Range

Single-point incremental forming (SPIF) is a flexible technology that can form a wide range of sheet metal products without the need for using punch and die sets. As a relatively cheap and die-less process, this technology is preferable for small and medium customised production. However, the SPIF technology has drawbacks, such as the geometrical inaccuracy and the thickness uniformity of the shaped part. This research aims to optimise the formed part geometric accuracy and reduce the processing time of a two-stage forming strategy of SPIF. Finite element analysis (FEA) was initially used and validated using experimental literature data. Furthermore, the design of experiments (DoE) statistical approach was used to optimise the proposed two-stage SPIF technique. The mass scaling technique was applied during the finite element analysis to minimise the computational time. The results showed that the step size during forming stage two significantly affected the geometrical accuracy of the part, whereas the forming depth during stage one was insignificant to the part quality. It was also revealed that the geometrical improvement had taken place along the base and the wall regions. However, the areas near the clamp system showed minor improvements. The optimised two-stage strategy successfully decreased both the geometrical inaccuracy and processing time. After optimisation, the average values of the geometrical deviation and forming time were reduced by 25% and 55.56%, respectively.

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