An investigation into thickness distribution in single point incremental forming using sequential limit analysis

• Published in: International journal of material forming Vol. 7; no. 4; pp. 469 - 477
• Main Authors: Mirnia, M. J., Mollaei Dariani, B., Vanhove, H., Duflou, J. R.
• Format: Journal Article
• Language: English
• Published: Paris Springer Paris 01.12.2014
• Subjects: CAE) and Design; Computational Intelligence; Computer-Aided Engineering (CAD; Engineering; Machines; Manufacturing; Materials Science; Mechanical Engineering; Original Research; Processes; Thickness; Second-order cone programming (SOCP); Single point incremental forming (SPIF); Sequential limit analysis
• ISSN: 1960-6206; 1960-6214
• DOI: 10.1007/s12289-013-1143-x

Single point incremental forming (SPIF), needing no dedicated tools, is the simplest variant of incremental sheet metal forming processes. In the present work, a simplified model of SPIF of a truncated cone, capable of predicting the thickness distribution, has been developed using sequential limit analysis (SLA). The obtained results were validated experimentally and compared with thickness predictions obtained from an explicit shell FE model implemented in Abaqus. It is shown that SLA is capable to solve the thickness prediction problem more accurately and efficiently than the equivalent FEA approach. As an application of the proposed model, the effect of the diameter of the hemispherical tool tip and the step down on the thickness distribution and the minimum thickness in a 50° cone is studied using SLA. By introducing bending and stretching zones in the wall of the cone, variations of the minimum thickness by changing the tool diameter and the step down are discussed.