A Comparative Study of Simulation Models on Incremental Forming Process by Using the Enhancement Tools

Abstract

Incremental Forming IF is a suitable sheet metal forming technique for producing complex forms by local deformation. The forming tool movement follows the designed tool path controlled by the CNC machine programme. The main categories of the process are single point, SP and two points, TP "with enhancement tools". Additionally, the product design determines the enhancement tool type used and its obstacles. The enhancement tools are used for improvement of the product profile quality, while maintaining the simplicity of the process. The material formability is affected by mechanical properties and characteristics of the product profile. The limits are concerning the forming tools used and the blank thickness. On the other hand, due to the difficult environment of these process models, numerical methodologies controlled by Finite Element Method, FEM are currently in extensive use. The research offers the main data and results of a comparing study on the influence of using the enhancement tools in IF through FEM. The study purposes to identify the scientific differences of the IF processes, "with and without enhancement tools" by evaluating the thickness and strains distribution of the deformed blank section. In addition, the analysis and the evaluation of the final product profile have been studied.