Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming.

Area of Science:

• Manufacturing Engineering
• Computational Mechanics
• Materials Science

Background:

• Single Point Incremental Forming (SPIF) is vital for small-batch sheet metal production.
• Current SPIF design relies on complex numerical simulations with long computational times.
• Challenges include long tool paths, problem complexity, and accurate path determination.

Purpose of the Study:

• To simplify Finite Element (FE) modeling of SPIF.
• To assess the impact of simplification on geometric accuracy and the bottom pillowing effect.
• To reduce computational time for SPIF simulations.

Main Methods:

• Performed FE analysis of an incrementally formed truncated pyramid using ABAQUS.
• Validated FE results with experimental data using DC04 low-carbon steel.
• Implemented mass scaling, time scaling, and an artificial neural network (ANN) for optimization.

Main Results:

• Mass and time scaling significantly reduce calculation time without compromising pillowing accuracy.
• ANN identified optimal mesh size and mass scaling for minimal bottom pillowing error.
• Smallest geometric error achieved with mass scaling of 19.01, tool velocity of 16.49 m/s, and 1x1 mm mesh size.

Conclusions:

• Simplified FE modeling with scaling techniques drastically cuts SPIF simulation time.
• ANN effectively optimizes parameters for improved accuracy and reduced pillowing.
• Methodology is applicable to other incrementally formed shapes, enhancing design efficiency.