Study On Numerical Simulation And Process Of Incremental Sheet Metal Forming

Incremental Sheet Metal Forming process (ISMFP) is an innovative sheet metal forming technology without dedicated dies based on computer, numerical control and plastic forming technology, which design numerical control program according to sheet metal forming requires. By this method, complex shell parts could be manufactured with flexibility, cost reduction and convenient and the metal flow could be controlled point by point. ISMFP is very suitable to produce small lot of batches and a variety of products, such as automobile, airplane, kitchenware products. But so far, the internal and international study on deformation's mechanism and control technology of ISMFP were still on the stage of explorative. In the application, ISMFP still exist some of the pressing need to address the question of how to select the reasonable technical parameters and how to avoid cracking and wrinkling in the forming. To solve these problems, the deformation mechanism of incremental sheet metal forming should be studied seriously. By Finite Element Method (FEM) numerical simulation, precise information such as stress distribution, strain and other thickness's data could be achieved directly and conveniently access to these valuable data used in the studying of forming mechanism. In the conventional sheet metal forming technology research, FEM has played an important role.Because of ISMFP's characteristic, the loading trajectory is complex and long, the thinning of the sheet thickness is non-uniform, and the local deformations are accumulated. So, there are some difficulties in the numerical simulation of incremental sheet metal forming. For example, the modeling of incremental sheet metal forming is difficult and the computational efficiency is low.Based on the nonlinear, elastic-plastic finite element method theory, the modeling approach of the numerical simulation of incremental sheet metal forming was studied firstly in this project. Through the establishment of model conformed to the practice, the involved nonlinear anisotropic elastic-plastic material model, the control strategies of the dynamic load of optimized trajectories and so on, the FEM model of Incremental Sheet Metal Forming was reasonably planed.According to modeling planning, the most representative parts as the truncated cone was used to modeling, Based on the elastic-plastic material model of the truncated cone, the ISMFP with different parameters were set up. Such as different tool's semidiameter, layer spacing and the loading trajectory of the forming and so on. The ISMFP with different parameters were simulated.Finally, the different process parameters on the impact of the shape forming, the non-uniform thinning of the metal sheet thickness, stress, strain and forming force were researched. Thus, provide a reasonable basis and reference for the selection of process parameters.