Numerical Simulation And Optimization Of Single Point Incremental Forming Process For Aluminum Alloy Sheets

The multi-pass single point forming process can form large-wall angle or straight wall parts and complex curved surfaces parts.For complex curved surface parts,the forming process can improve the forming quality,but only requires some simple support models.Support model materials can choose resin,wood,etc.which are fabricated and changed easily.The single point incremental forming process is the suitable for small batch production and rapid prototype.In this paper,the commonly used industrial aluminum alloy 1060 Al be used in the simulution and experments.Aluminum alloy has many advantages,such as good plastic properties,easy to form,and is widely used in industrial production.So in this paper 1060 Al be used to study the uniformity and formability of straight-walled cylindrical parts by numerical simulation and experimental study.Then determined the best process parameters and used the optimized process parameters developed composite parts.Because the forming trajectory directly affects the forming quality.This paper has formulated two forming strategies and established related models through finite element to study the effect of forming quality.Obtain the forming strategy that can effectively improve the forming quality of the material.However,the large number of forming process parameters should be studied in the forming process.Therefore,the single-factor comparative study of the process parameters is carried out.The minimum thickness of the formed part and the distribution of the thickness of the formed part which influence of the feed speed and the size of the cylinder radius and the forming depth are taken as targets to study.The result is that the radius of the forming tool has a positive relationship with the minimum thickness of the formed sheet and the uniformity of the formed part.The relationship between the distance between the lower layer and the feed rate is the inverse relationship with the minimum thickness of the formed sheet and the uniformity of the formed part.The different radii of the cylindrical element have a minor influence on the forming depth,and the forming depth has the most direct influence on the formability of the formed part.Then,the influence of multiple factors on the minimum thickness of the sheet was further studied,and the parameters were further optimized.It was found that the formability of the straight-walled part was improved,and the relationship between the relevant parameters was further determined by the response surface method.The resulting rule was applied to the formation of more complex parts,using four passes,forming tool radius of 5 mm,pressing distance of 0.75 mm,and feed rate of 700 mm/min.Then,used the process parameter combination separately formed cylindrical parts with a maximum diameter of 120 mm and depth of 40 mm,and the complex square boxes with a maximum side length of 120 mm and a depth of 40 mm.Finally,the complex cylindrical parts and complex box parts with better forming quality are obtained,and it was verified that the optimized combination of parameters improves the formability of the material to some extent.Then through the trial production of more exotic parts,the rationality of the used parameters was further confirmed.