Parameters for the FEA simulations of single point incremental forming

Abstract

Single point incremental forming has shown immense potential in the manufacture of prototypes. The sheet metal deformation in this technique is carried out by a small hemispherical or flat tool that moves from the sheet periphery to the sheet center while also pushing the sheet down. Simulations of single point incremental forming can be a tedious task since the area required to be formed is large and the two sheet contact area is fairly small. The effect of tool however, affects the entire geometry by causing deflections and radial strains. Hence, it becomes essential to understand the effect of certain parameters that influence the simulation results for this forming process. The paper aims to study factors influencing the simulation of single point incremental forming process. It gives a description of techniques employed to simulate non-linear behavior of sheet metal forming along with the implicit and explicit methodology. Information on the selection of element type including Reduced Enhanced Solid-Shell element is presented. Techniques employed to avoid locking are also discussed.