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Enhancing/Improving Forming Limit Curve and Fracture Height Predictions in the Single-Point Incremental Forming of
Trung-Kien Hoang1, The-Thanh Luyen2, Duc-Toan Nguyen3
1Faculty of Mechanical Engineering, Thainguyen University of Technology, Thainguyen 250000, Vietnam.
Materials (Basel, Switzerland)
|December 9, 2023
Summary
This study enhances defect prediction in Single-Point Incremental Forming (SPIF) by improving the forming limit curve (FLC) accuracy. A novel method using variable tool radii in simulations significantly reduces fracture prediction errors for Al1050 sheets.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Computational Mechanics
Background:
- Single-Point Incremental Forming (SPIF) offers cost-effective, mold-independent manufacturing, ideal for small batches.
- Predicting defects, especially fracture, is crucial for SPIF success but challenging due to material and shape complexities.
- Numerical simulations are vital for preemptive defect analysis in SPIF.
Purpose of the Study:
- To investigate the role of the forming limit curve (FLC) in predicting fractures during SPIF simulations.
- To develop an enhanced method for constructing the forming limit curve at fracture (FLCF) for improved SPIF defect prediction.
- To validate the proposed FLCF enhancement through simulations and experiments on truncated cone parts.
Main Methods:
- Constructed the FLC for Al1050 using the Modified Maximum Force Criterion (MMFC).
- Developed a graphical approach to predict FLCF from uniaxial and bi-axial tensile deformation data.
- Proposed a novel FLCF prediction method utilizing SPIF simulations with variable tool radii and strain analysis.
- Validated the enhanced FLCF model through simulations and experiments of truncated cone parts with varying wall angles.
Main Results:
- Initial FLCF predictions showed a 15.97% deviation in fracture height between simulation and experiment for truncated cones.
- The novel FLCF prediction method, based on variable tool radii simulations, demonstrated substantial alignment in fracture height with experimental results for truncated cones.
- The enhanced FLCF model significantly improved the accuracy of fracture prediction in SPIF simulations.
Conclusions:
- Accurate FLCF prediction is critical for reliable SPIF simulations and defect mitigation.
- The proposed method using variable tool radii simulations offers a more precise approach to FLCF construction for SPIF.
- This research advances SPIF capabilities by improving defect prediction, broadening its industrial applicability.
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