Numerical simulation of incremental forming of sheet metal

Applicability of numerical technique to incremental forming of sheet metal is examined. A dynamic explicit finite element code DYNA3D is used. Assumed product shape is quadrangular pyramid and there are two variations in its height. The traveling pattern of the tool is basically square loop in accordance with the final shape. The tool head is hemispherical. The tool forces the sheet to deform plastically around the contact area. Effect of traveling speed of the tool and the density of the sheet material are pre-examined to determine the computational condition for the practical use of the code, and the computational condition is optimized for shortening the computing time without inertial effect of the material on deformation behavior. Effect of the tool path on the deformation behavior is also examined with respect to several tool paths. Calculated deformation shapes are compared among tool paths and the distribution of thickness strain is also discussed. Furthermore, the force acting on the traveling tool is also evaluated. It is concluded that the numerical simulation might be exploited for optimization of the incremental forming process of sheet metal. (C) 2007 Elsevier B.V. All rights reserved.