Numerical Simulation And Process Research For Metal Sheet Single Point Incremental Forming

Single Point Incremental Forming is a kind of flexible manufacturing process which control the forming path of tool head by Program to form the trajectory of three-dimensional layer by layer and achieve a continuous sheet metal forming part. The kind of sheet metal forming process does not require the traditional sheet metal forming die during the forming process. It could be used in small quantity and variety, complex shape forming of sheet metal parts processing and prototyping. It is an advanced manufacturing technology with a very broad application prospects and development of future.The present paper analyzes the stress-strain state of single point incremental forming process according to Theory of metal forming, propose the control principles of single point incremental forming process, deduce the thickness and the thinning rate of the thickness of single point incremental forming, provide theoretical basis for the selection of parameters.Single Point Incremental Forming is divided into single point incremental forming with mold and without mold according to the different ways of forming. The two ways of forming is analyzed and establish the finite element model of TA2 using ANSYS/LS-DYNA software. The influence of different parameters of single point incremental forming process to the quality of forming parts by changing the radius forming tool head size, the amount of vertical offset, horizontal offset, sheet thickness, the friction parameters between tool head and the sheet metal is investigated by using numerical simulation. The rules is discovered to optimize the forming parameters in test. The difference of the two single-point incremental forming methods is shown by stress and strain analysis, forming accuracy, thickness distribution, the size reduction rate. And the strain history and thickness change history of deformation zone of sheet is used to understand the deformation mechanism of single point incremental forming.TA2 pure titanium, 304 stainless steel and 1060 pure aluminum sheet is formed by single point incremental forming process. First of all, analyze the shape, size and material of required parts, then select the reasonable parameters, establish the finite element model using ANSYS/LS-DYNA software to simulate the forming process. The simulation results is analyzed, and then actually form the required parts by single Point incremental forming machine. TA2 pure titanium sheet metal forming failure because the tonnage of the existing machine is not enough and severe wear between the tool and sheet.material have accumulated in some areas of sheet as 304 stainless steel is illiquid, so the surface of the forming parts fold, but did not rupture. the surface of the forming parts do not fold as 1060 pure aluminum is liquid, but 1mm sheet rupture during the forming process, 2mm sheet did not.