Finite element simulations and experimental verifications for forming limit curve determination of two-layer aluminum/brass sheets considering the incremental forming process

2021 ◽  
pp. 146442072110452
Author(s):  
A. Jalali ◽  
R. Hashemi ◽  
M. Rajabi ◽  
P. Tayebi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Incremental Forming ◽  
Bottom Layer ◽  
Finite Element Simulations ◽  
Experimental Results ◽  
Forming Limit ◽  
Forming Process ◽  
Simulation Results ◽  
Aluminum 1050

In this paper, forming limit diagram (FLD) of aluminum/brass two-layer sheets through an incremental forming process (ISF) was studied numerically and experimentally. At first, the two-layer aluminum 1050/brass (65% copper) sheets were fabricated using the roll bonding process. Also, the finite element simulations of the incremental forming process with ABAQUS software were utilized to predict the FLD. For this purpose, the criterion of the second derivative of the equivalent plastic strain was used to predict fracture. Finally, the numerical simulation results were compared with the experimental results. For instance, comparing experimental and numerical FLD0 values for the formed samples with forming angle 62.5-degree showed a 7% difference. However, the difference was negligible, and numerical simulation results could be used with an appropriate reliability coefficient. The effect of sheet arrangement towards tools was then investigated. It finds out from the experimental results that the formability of the Brass/Al (brass was up layer and aluminum was bottom layer) was more than the Al/Brass (aluminum is up layer and brass is bottom layer). In the following, the ISF parameters such as forming limit angle, step-down, and thickness distribution were investigated.

Comparison between an Advanced Numerical Simulation of Sheet Incremental Forming Using Adaptive Remeshing and Experimental Results

2013 ◽  
Vol 554-557 ◽  
pp. 1375-1381 ◽  
Author(s):  
Laurence Giraud-Moreau ◽  
Abel Cherouat ◽  
Jie Zhang ◽  
Houman Borouchaki
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Sheet Metal ◽  
Metal Forming ◽  
Tool Path ◽  
Incremental Forming ◽  
Computation Time ◽  
Experimental Results ◽  
Forming Process ◽  
Adaptive Remeshing

Recently, new sheet metal forming technique, incremental forming has been introduced. It is based on using a single spherical tool, which is moved along CNC controlled tool path. During the incremental forming process, the sheet blank is fixed in sheet holder. The tool follows a certain tool path and progressively deforms the sheet. Nowadays, numerical simulations of metal forming are widely used by industry to predict the geometry of the part, stresses and strain during the forming process. Because incremental forming is a dieless process, it is perfectly suited for prototyping and small volume production [1, 2]. On the other hand, this process is very slow and therefore it can only be used when a slow series production is required. As the sheet incremental forming process is an emerging process which has a high industrial interest, scientific efforts are required in order to optimize the process and to increase the knowledge of this process through experimental studies and the development of accurate simulation models. In this paper, a comparison between numerical simulation and experimental results is realized in order to assess the suitability of the numerical model. The experimental investigation is realized using a three-axis CNC milling machine. The forming tool consists in a cylindrical rotating punch with a hemispherical head. A subroutine has been developed to describe the tool path from CAM procedure. A numerical model has been developed to simulate the sheet incremental forming process. The finite element code Abaqus explicit has been used. The simulation of the incremental forming process stays a complex task and the computation time is often prohibitive for many reasons. During this simulation, the blank is deformed by a sequence of small increments that requires many numerical increments to be performed. Moreover, the size of the tool diameter is generally very small compared to the size of the metal sheet and thus the contact zone between the tool and the sheet is limited. As the tool deforms almost every part of the sheet, small elements are required everywhere in the sheet resulting in a very high computation time. In this paper, an adaptive remeshing method has been used to simulate the incremental forming process. This strategy, based on adaptive refinement and coarsening procedures avoids having an initially fine mesh, resulting in an enormous computing time. Experiments have been carried out using aluminum alloy sheets. The final geometrical shape and the thickness profile have been measured and compared with the numerical results. These measurements have allowed validating the proposed numerical model. References [1] M. Yamashita, M. Grotoh, S.-Y. Atsumi, Numerical simulation of incremental forming of sheet metal, J. Processing Technology, No. 199 (2008), p. 163 172. [2] C. Henrard, A.M. Hbraken, A. Szekeres, J.R. Duflou, S. He, P. Van Houtte, Comparison of FEM Simulations for the Incremental Forming Process, Advanced Materials Research, 6-8 (2005), p. 533-542.

scholarly journals The Effect of Swinging Ball Heads with Different Arrangements in Multi-Point Stretch-Forming Process

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 337 ◽  
Author(s):  
Jian Xing ◽  
Yan-yan Cheng ◽  
Zhuo Yi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Sheet Metal ◽  
Strain Distribution ◽  
Finite Element Models ◽  
Stretch Forming ◽  
Forming Process ◽  
Forming Quality ◽  
Staggered Arrangement ◽  
Simulation Results

To improve the effect of multi-point stretch forming of sheet metal, it is proposed in this paper to replace a fixed ball head with a swinging ball head. According to the multi-point dies with different arrangements, this research establishes finite element models of the following stretch forming, i.e., fixed ball heads with conventional arrangement, swinging ball heads with conventional arrangement, swinging ball heads with declining staggered arrangement, and swinging ball heads with parallel staggered arrangement, and then numerical simulation is performed. The simulation results show that by replacing a fixed ball head with a swinging ball head, the surface indentation of the part formed was effectively suppressed, the stress and tension strain distribution of the part formed was improved, and the forming quality was improved; the thickness of the elastic pad was reduced, the springback was reduced and the forming accuracy was improved; and when the ball head was applied to a multi-point die with staggered arrangement, a better forming result was achieved, where the best forming result was achieved in combining the swinging ball heads with the multi-point die with a parallel staggered arrangement. Forming experiments were carried out, and the experimental results were consistent with the trend of numerical simulation results, which verified the correctness of the numerical simulation.

Study on the Forming Process of the Crossmember in Car Intermediate Floor

2013 ◽  
Vol 442 ◽  
pp. 593-598
Author(s):  
Xue Xia Wang ◽  
Peng Chong Guan ◽  
Hai Peng Li ◽  
Li Hui Wang ◽  
Na Zhang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Numerical Model ◽  
Process Parameters ◽  
Thickness Distribution ◽  
Forming Limit Diagram ◽  
Forming Limit ◽  
Simulation Technology ◽  
Forming Process ◽  
Distribution Diagram ◽  
Simulation Results

Flanging and bending forming processes of the crossmember in car intermediate floor are investigated respectively by using numerical simulation technology. The numerical model of the crossmember was established and its press forming effect was simulated to determine the feasible process parameters affecting its manufacturability. Forming limit diagram and thickness distribution diagram are used to evaluate simulation results of different process schemes. And then optimum values of process parameters for flanging and bending are found, which can reduce the tendencies of wrinkling, springback and crackling during the stamping of the product.

Finite Element Simulations Of Multi Stage Incremental Forming Process

2018 ◽  
Vol 5 (2) ◽  
pp. 3802-3810 ◽  
Author(s):  
Kurra Suresh ◽  
Srinivasa Prakash Regalla ◽  
Nitin Kotkundae
Keyword(s):  
Finite Element ◽  
Incremental Forming ◽  
Finite Element Simulations ◽  
Forming Process ◽  
Multi Stage

Single-point incremental forming of sheet metals: Experimental study and numerical simulation

2016 ◽  
Vol 231 (2) ◽  
pp. 301-312 ◽  
Author(s):  
Matteo Benedetti ◽  
Vigilio Fontanari ◽  
Bernardo Monelli ◽  
Marco Tassan
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Incremental Forming ◽  
Single Point ◽  
Integration Scheme ◽  
Al Alloy ◽  
Single Point Incremental Forming ◽  
Sheet Metals ◽  
Forming Process ◽  
Starting Point

In this article, the single-point incremental forming of sheet metals made of micro-alloyed steel and Al alloy is investigated by combining the results of numerical simulation and experimental characterization, performed during the process, as well as on the final product. A finite element model was developed to perform the process simulation, based on an explicit dynamic time integration scheme. The finite element outcomes were validated by comparison with experimental results. In particular, forming forces during the process, as well as the final shape and strain distribution on the finished component, were measured. The obtained results showed the capability of the finite element modelling to predict the material deformation process. This can be considered as a starting point for the reliable definition of the single-point incremental forming process parameters, thus avoiding expensive trial-and-error approaches, based on extensive experimental campaigns, with beneficial effects on production time.

Numerical Simulation for the Multi-Point Incremental Forming Process

2015 ◽  
Vol 775 ◽  
pp. 219-223
Author(s):  
Wan Mian Yang ◽  
Yuan Xin Luo ◽  
Zhi Fang Liu ◽  
Ru Xu Du
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Finite Element Model ◽  
Sheet Metal ◽  
Incremental Forming ◽  
Element Model ◽  
Sheet Metals ◽  
Forming Force ◽  
Forming Process ◽  
Thickness Change

Multi-point forming process has been developed to shape the sheet metal with bidirectional curvature. However, the forming force usually climbs too high so that the dimension of the forming machine should be designed to meet it. To solve this problem, the multi-point incremental forming (MPIF) process was proposed in this paper. First, the principle of this new forming process was introduced. Then, the experimental device was designed. Next, the MPIF process was simulated by a finite element model. The forming effects including displacements, thickness, and curvatures were visualized and discussed in detail. It was found that there is no obvious thickness change during the forming process. The advantage of this forming process is that the shape of the sheet metals adaptable and controllable with small forming force.

Upsetting Process Analysis and Numerical Simulation of Metal Pipe’s End

2013 ◽  
Vol 364 ◽  
pp. 488-492 ◽  
Author(s):  
Yong Lei Su ◽  
Wu Zi Yang ◽  
Chang Ping Wang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Deformation Zone ◽  
Process Analysis ◽  
New Technology ◽  
Good Match ◽  
Forming Process ◽  
Conical Die ◽  
Metal Deformation ◽  
Simulation Results

Upsetting is a common method in the production of connectors, a new technology to avoid instability of long pipe under compression was taken in this paper, which would get the upsetting shape of long pipe by changing the length of deformation zone. Forming process was simulated by finite element, and some mechanisms of metal deformation and load were obtained. The simulation results showed that: instability was not occurred and one could have specified shape by using conical die upsetting only once. Then the upsetting experiment was conducted, the trail had a good match with simulation results, which expanded upsetting rules, and provided a reference for design of die.

scholarly journals The Effect of Swinging Ball Heads with Different Arrangements in Multi-Point Stretch Forming Process

2019 ◽  
Author(s):  
Jian Xing ◽  
Yan-yan Cheng ◽  
Zhuo Yi
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Strain Distribution ◽  
Finite Element Models ◽  
Stretch Forming ◽  
Forming Process ◽  
Forming Quality ◽  
Staggered Arrangement ◽  
Simulation Results ◽  
Formed Part

To improve the effect of multi-point stretch forming of sheet metal, it is proposed in this paper to replace fixed ball head with swinging ball head. According to the multi-point dies with different arrangements, this research establishes the finite element models of the following stretch forming, i.e. fixed ball heads with conventional arrangement, swinging ball heads with conventional arrangement, swinging ball heads with declining staggered arrangement, and swinging ball heads with parallel staggered arrangement and then numerical simulation is performed. The simulation results show that by replacing fixed ball head with swinging ball head, the surface indentation of the formed part was effectively suppressed, the stress and tension strain distribution of the formed part was improved and the forming quality was improved; that the thickness of the elastic pad was reduced, the springback was reduced and the forming accuracy was improved; and that when the ball head was applied to multi-point die with staggered arrangement, better forming result was achieved, where the best forming result was achieved in combining the swinging ball heads with the multi-point die with parallel staggered arrangement. The forming experiments were carried out, and the experimental results were consistent with the trend of numerical simulation results, which verified the correctness of the numerical simulation.

Forming Limit in the Nosing Process of Micro Copper Cups

2019 ◽  
Vol 794 ◽  
pp. 121-126
Author(s):  
Chao Cheng Chang ◽  
Shuo Kai Pan ◽  
Kuan Te Yu
Keyword(s):  
Finite Element ◽  
Friction Factor ◽  
Wall Thickness ◽  
Finite Element Simulations ◽  
Forming Limit ◽  
Two Stage ◽  
Micro Scale ◽  
Backward Extrusion ◽  
Simulation Results ◽  
Good Agreement

This study used finite element simulations and experiments to investigate the forming limit in the nosing process of micro copper cups, and to establish the limit nosing curves in terms of nosing ratio, die angle, and friction factor. Two-stage processes, including backward extrusion and nosing processes, were considered in simulations and experiments at micro scale. The copper billets with 1 mm diameter and length were backwards extruded to produce the 1 mm diameter cups with 0.1 mm wall thickness. The cups were later used in the nosing processes under different forming conditions. By analysing the results of the nosed cups from the simulations, it is possible to identify the safe and failure forming conditions and establish the limit nosing curves for the nosing process. The simulation results show that the limit nosing ratio increases as the die angle or friction factor decreases. Two predicted results for poor and well lubricated conditions have been examined and are in good agreement with those from experiments. The study not only explores the characteristics of the noise process of copper cups at micro scale but also establishes the limit nosing curves which could be the guidelines for the design of micro metal components.

Sign in / Sign up

Export Citation Format

Share Document