FEM model computing large deformation in metal sheet forming by high power beam

The use of high power beam technologies like the laser and the plasma arc has provided a mould-less metal sheet rapid forming technique. This technique can have application either for rapid prototyping and rapid manufacturing of mechanical products. The virtual manufacturing can be a boost for a rapid diffusion of the mould-less sheet forming. Even if the calculations can be cumbersome, the Finite Element Analysis (FEM) is unique for providing geometrical and physical information on product development and manufacturing via computer. Herein, a simplified FEM model for both laser and plasma arch is proposed. In particular, the heat source has been modeled so the computation is easier and faster. The model was validated by comparison with the experimental results and it is able to predict the forming angle, the final shape, and the residual stress of metal sheet induced by high power beam irradiation.