Optimization of Single-Point Incremental Forming of Polymer Sheets through FEM

Area of Science:

• Materials Science
• Manufacturing Engineering
• Polymer Processing

Background:

• Incremental sheet forming (ISF) is a flexible manufacturing process for customized components.
• ISF offers advantages like simple tooling, low cost, and high formability.
• Thermoplastic sheets formed via ISF often exhibit defects such as twisting and wrinkling.

Purpose of the Study:

• To investigate the impact of different toolpath strategies on the incremental forming of polycarbonate sheets.
• To identify a toolpath strategy that optimizes the ISF process for polymer sheets.
• To analyze forming forces, deformation, energy consumption, and manufacturing time.

Main Methods:

• Numerical analysis using a commercial finite element code.
• Simulation of incremental forming process for polycarbonate sheets.
• Systematic variation of toolpath strategies, including alternating diagonal up and vertical down steps.

Main Results:

• Toolpaths alternating diagonal up and vertical down steps significantly reduce forming forces.
• These optimized toolpaths are presumed to decrease the risk of defects like twisting and wrinkling.
• The identified strategies positively impact energy consumption and do not substantially increase manufacturing time.

Conclusions:

• Specific toolpath strategies can optimize the incremental forming of polycarbonate sheets.
• The optimized strategies offer reduced forming forces, fewer defects, and improved energy efficiency.
• This research provides a pathway for more efficient and defect-free polymer sheet forming using ISF.