An efficient force prediction strategy for single point incremental sheet forming

Incremental sheet forming is a flexible forming process where a tool is programmed to follow predetermined tool paths to create sheet metal parts. It is ideal for rapid prototyping and low-volume production. Modeling incremental sheet forming and predicting forming forces can significantly benefit product design and process development. Existing force prediction methods are either inaccurate or too time consuming. The goal of this research is to identify an efficient force prediction strategy based on experimental observations of forming forces. It was found that by creating a near-finished part geometry as a starting point of numerical simulation, forming forces can be predicted with satisfactory accuracy and efficiency. The proposed strategy was validated and further demonstrated in forming of parts having different geometries. As the simulation strategy can be completed in a fraction of the full simulation time, it can be adopted to guide the development of incremental sheet forming parts.