Finite element method study of incremental sheet forming for complex shape and its improvement

Abstract

In order to improve the incremental sheet forming process for the product of complex shape (e.g. human face), a combination of both computer-aided manufacturing (CAM) and finite-element modelling (FEM) simulation, is implemented and evaluated from the histories of stress and strain value by means of finite-element analysis. Here, the results, using ABAQUS/Explicit finite-element code, are compared with forming limit curve at fracture in order to predict and improve the forming conditions by changing process variables of tool radius, tool down-step, and friction coefficient according to the orthogonal array of Taguchi's method. First, the CAM simulation is used to create cutter location data. This data are then calculated, modified, and exported to the input file format required by ABAQUS through using MATLAB programming. The FEM results are implemented for negative incremental sheet forming and then investigated by experiment.