Numerical Simulation For Sheet Metal Digital Incremental Forming

With introducing Layered Manufacture (LM) method into the sheet metal processing, Sheet metal Incremental Forming, which realizes the flexibility of sheet metal forming, processes sheet metal layer by layer with the increments of continuous local plastic forming along the programmed trajectory. The technology can directly manufacture workpieces with the shape of sheet, and the machining precision is very high because the metal plate is pressed only in some parts of the plate and the distortion is accumulated continuously to form whole shape. The importance of the technology is easy automatization during whole process (from modeling to CAE analysis and to machining contour). All of these characteristics make the technology become a advance manufacture technology which has a development future. Since the technology of the metal layered incremental forming process is realitively complicated, and various parameters such as layer depth ,distributing of leaving and approaching point and process mark are difficult to choose by the experimental methods, it is the key factor for sheet metal digital forming process to choose reasonable technology parameters to get ideal process workpiece. The sheet metal layered forming process is a multi-stage forming process, the paper introduce FEM simulation project of sheet metal layered forming process. In this thesis, by using FEM software-LS-DYNA, we simulate the process of sheet metal Incremental Forming. The foundation of the FEM model is based on characteristic of the experiment, the tooling track and loading manner have being built in a simple way, at the same time, according to the characteristic of the experiment equipment, we have also built the boundary condition and restriction. Such process have guaranteed the facticity of the simulation. And based on this model ,the distributing characteristic of stress and strain has been analysed, some key factor such as layer depth,leaving and approaching movement of the tooling head have been discussed here, and the form of point support has also been studied.