Fem Analysis For Instability And Springback Of Sheet Metal Incremental Forming

Sheet metal incremental forming process a flexible processing technology which adopts the method of"Layered Manufacturing". It can develop new product fast, economically and in high quality without or only with simple die. Therefore, this technology is especially suited to develop small batch, diverse products. It has a wonderful market prospect in aviation, automobile panels and other fields.The springback and instability of the formed parts in sheet metal incremental forming process has great negative impact on the shape and dimension accuracy. So it required a lot of research in this area. In conventional physics experiments, we can only observe some local phenomenon, and get the final results. Finite element method (FEM) can supply us with detailed information of stress, strain and other mechanical parameters which can help us in analysing the reasons of the experimental phenomena, and finally getting the solution.In this study, we simulated the incremental forming process, instability and springback of the formed parts, and also analysed the results. Firstly, the full simulation of the incremental forming process of a forming part with unsymmetrical surface was completed. Then we analysed the changing history of the stress, strain, and thickness of the blank. Secondly, the instability phenomenon of forming the parabolic shaped part was simulated. Then we got the reason of the problem, and finally a solution was given. Thirdly, we analysed the essence of the springback which was divided into three parts: springback of forming process, springback of uninstalling the force of the clamp, springback of trimming. The first two parts was simulated, and some conclusions were made according to the result of simulating. At last, an idea of closed-loop springback compensation with FEM simulation based on Fourier transform was presented.