Investigation of the effect of forming parameters in incremental sheet forming using a micromechanics based damage model
Source abstract
Abstract
The incremental sheet forming (ISF) process is considered as a feasible solution for forming a variety of small batch and even customised sheet components. The quality of an ISF product is affected by various process parameters, e.g. sheet material, step-down, feed rate, tool diameter and lubricant. To produce an ISF part of sufficient quality and accuracy without defects, optimal parameters of the ISF process should be selected. In the present work, experiments and FE analyses were conducted to evaluate the influence of the main ISF process parameters including the step-down, feed rate and tool diameter on the formability and fracture of two types of pure Ti (grade 1 and 2). The Gurson–Tvergaard-Needleman (GTN) damage constitutive model with consideration of stress triaxiality was developed to predict ductile fracture in the ISF process due to void nucleation, growth and coalescence. It was found that the ISF parameters have varying degrees of effect on the formability and fracture occurrence of the two types of pure Ti, and grade 2 pure Ti sheet is more sensitive than grade 1 Ti sheet to the forming parameters due to low ductility.
Source: openalex_inverted_index · Quality: baseline
Research context
OpenAlex topics: Metal Forming Simulation Techniques · Metallurgy and Material Forming · Advanced Surface Polishing Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (40)
Show source-provided references
1. Gatea S, Ou H, McCartney G (2016) Review on the influence of process parameters in incremental sheet forming. The International Journal of Advanced Manufacturing Technology p. 1–2110.1007/s00170-016-8426-6 ↗
2. Han F, Mo J-h (2008) Numerical simulation and experimental investigation of incremental sheet forming process. J Cent S Univ Technol 15(5):581–58710.1007/s11771-008-0109-5 ↗
3. Jun-chao L, Chong L, Zhou T-g (2012) Thickness distribution and mechanical property of sheet metal incremental forming based on numerical simulation. Trans Nonferrous Metals Soc China 22:s54–s6010.1016/S1003-6326(12)61683-5 ↗
4. Ambrogio G, Filice L, Fratini L, Micari F (2004) Process mechanics analysis in single point incremental forming. In AIP Conference Proceedings. AIP10.1063/1.1766645 ↗
5. Duflou J, Tunçkol Y, Szekeres A, Vanherck P (2007) Experimental study on force measurements for single point incremental forming. J Mater Process Technol 189(1):65–7210.1016/j.jmatprotec.2007.01.005 ↗
6. Ham M, Jeswiet J (2006) Single point incremental forming and the forming criteria for AA3003. CIRP Ann Manuf Technol 55(1):241–24410.1016/S0007-8506(07)60407-7 ↗
7. Bhattacharya A, Maneesh K, Venkata Reddy N, Cao J (2011) Formability and surface finish studies in single point incremental forming. J Manuf Sci Eng 133(6):06102010.1115/1.4005458 ↗
8. Decultot N, Robert L, Velay V, Bernhart G (2010) Single point incremental sheet forming investigated by in-process 3D digital image correlation. EPJ Web of Conferences 6:1100110.1051/epjconf/20100611001 ↗
9. Fritzen D, Daleffe A, Castelan J, Schaeffer L (2013) Brass 70/30 and incremental sheet forming process. Key Eng Mater 554:1419–143110.4028/www.scientific.net/KEM.554-557.1419 ↗
10. Kim YS, Lee HJ, Park JG, Nguyen DT (2010) Finite element method study of incremental sheet forming for complex shape and its improvement. Proc Inst Mech Eng B J Eng Manuf 224(6):913–92410.1243/09544054JEM1825 ↗
11. Ham M, Jeswiet J (2007) Forming limit curves in single point incremental forming. CIRP Ann Manuf Technol 56(1):277–28010.1016/j.cirp.2007.05.064 ↗
12. Silva MB, Nielsen PS, Bay N, Martins PAF (2011) Failure mechanisms in single-point incremental forming of metals. Int J Adv Manuf Technol 56(9–12):893–90310.1007/s00170-011-3254-1 ↗
13. Centeno G, Bagudanch I, Martínez-Donaire AJ, García-Romeu ML, Vallellano C (2014) Critical analysis of necking and fracture limit strains and forming forces in single-point incremental forming. Mater Des 63:20–2910.1016/j.matdes.2014.05.066 ↗
14. Buffa G, Campanella D, Fratini L (2013) On the improvement of material formability in SPIF operation through tool stirring action. Int J Adv Manuf Technol 66(9-12):1343–135110.1007/s00170-012-4412-9 ↗
15. Kim Y, Park J (2002) Effect of process parameters on formability in incremental forming of sheet metal. J Mater Process Technol 130:42–4610.1016/S0924-0136(02)00788-4 ↗
16. Hussain G, Gao L, Hayat N, Cui Z, Pang Y, Dar N (2008) Tool and lubrication for negative incremental forming of a commercially pure titanium sheet. J Mater Process Technol 203(1):193–20110.1016/j.jmatprotec.2007.10.043 ↗
17. Hussain G, Gao L, Zhang Z (2008) Formability evaluation of a pure titanium sheet in the cold incremental forming process. Int J Adv Manuf Technol 37(9):920–92610.1007/s00170-007-1043-7 ↗
18. Attanasio A, Ceretti E, Giardini C, Mazzoni L (2008) Asymmetric two points incremental forming: improving surface quality and geometric accuracy by tool path optimization. J Mater Process Technol 197(1):59–6710.1016/j.jmatprotec.2007.05.053 ↗
19. Hagan E, Jeswiet J (2004) Analysis of surface roughness for parts formed by computer numerical controlled incremental forming. J Eng Manuf 218(Part B):1307–131210.1243/0954405042323559 ↗
20. Oleksik V, Pascu A, Deac C, Fleacă R, Bologa O, Racz G (2010) Experimental study on the surface quality of the medical implants obtained by single point incremental forming. Int J Mater Form 3(S1):935–93810.1007/s12289-010-0922-x ↗
21. Silva PJ, Leodido LM, Silva CRM (2013) Analysis of incremental sheet forming parameters and tools aimed at rapid prototyping. In Key Engineering Materials. Trans Tech Publ10.4028/www.scientific.net/KEM.554-557.2285 ↗
22. Ai S, Lu B, Chen J, Long H, Ou H (2017) Evaluation of deformation stability and fracture mechanism in incremental sheet forming. Int J Mech Sci 124:174–18410.1016/j.ijmecsci.2017.03.012 ↗
23. Fang Y, Lu B, Chen J, Xu DK, Ou H (2014) Analytical and experimental investigations on deformation mechanism and fracture behavior in single point incremental forming. J Mater Process Technol 214(8):1503–151510.1016/j.jmatprotec.2014.02.019 ↗
24. Gatea S, Ou H, Lu B, McCartney G (2017) Modelling of ductile fracture in single point incremental forming using a modified GTN model. Eng Fract Mech 18610.1016/j.engfracmech.2017.09.021 ↗
25. Jackson K, Allwood J (2009) The mechanics of incremental sheet forming. J Mater Process Technol 209(3):1158–117410.1016/j.jmatprotec.2008.03.025 ↗
26. Malhotra R, Xue L, Cao J, Belytschko T (2011) Identification of deformation mechanisms responsible for failure in incremental forming using a damage based fracture model. AIP Conf Proc 1383(1):469–47610.1063/1.3623646 ↗
27. Malhotra R, Xue L, Belytschko T, Cao J (2012) Mechanics of fracture in single point incremental forming. J Mater Process Technol 212(7):1573–159010.1016/j.jmatprotec.2012.02.021 ↗
28. Martins PAF, Bay N, Skjoedt M, Silva MB (2008) Theory of single point incremental forming. CIRP Ann Manuf Technol 57(1):247–25210.1016/j.cirp.2008.03.047 ↗
29. Silva MB, Skjoedt M, Martins PAF, Bay N (2008) Revisiting the fundamentals of single point incremental forming by means of membrane analysis. Int J Mach Tool Manu 48(1):73–8310.1016/j.ijmachtools.2007.07.004 ↗
30. Gurson AL (1977) Continuum theory of ductile rupture by void nucleation and growth: part I—yield criteria and flow rules for porous ductile media. J Eng Mater Technol 99(1):2–1510.1115/1.3443401 ↗
31. Tvergaard V, Needleman A (1984) Analysis of the cup-cone fracture in a round tensile bar. Acta Metall 32(1):157–16910.1016/0001-6160(84)90213-X ↗
32. Gatea S, Xu D, Ou H, McCartney G (2017) Evaluation of formability and fracture of pure titanium in incremental sheet forming. The International Journal of Advanced Manufacturing Technology p. 1–17
33. Tvergaard V (1982) Influence of void nucleation on ductile shear fracture at a free surface. J Mech Phys Solids 30(6):399–42510.1016/0022-5096(82)90025-4 ↗
34. Nahshon K, Hutchinson J (2008) Modification of the Gurson model for shear failure. Eur J Mech A Solids 27(1):1–1710.1016/j.euromechsol.2007.08.002 ↗
35. Nielsen KL, Tvergaard V (2010) Ductile shear failure or plug failure of spot welds modelled by modified Gurson model. Eng Fract Mech 77(7):1031–104710.1016/j.engfracmech.2010.02.031 ↗
36. Isik K, Silva MB, Tekkaya AE, Martins PAF (2014) Formability limits by fracture in sheet metal forming. J Mater Process Technol 214(8):1557–156510.1016/j.jmatprotec.2014.02.026 ↗
37. Chen Z, Dong X (2009) The GTN damage model based on Hill’48 anisotropic yield criterion and its application in sheet metal forming. Comput Mater Sci 44(3):1013–102110.1016/j.commatsci.2008.07.020 ↗
38. Kami A, Dariani BM, Vanini AS, Comsa DS, Banabic D (2015) Numerical determination of the forming limit curves of anisotropic sheet metals using GTN damage model. J Mater Process Technol 216:472–48310.1016/j.jmatprotec.2014.10.017 ↗
39. Bae D, Ghosh A (2002) Cavity growth during superplastic flow in an Al–Mg alloy: I. Experimental study. Acta Mater 50(5):993–100910.1016/S1359-6454(01)00399-8 ↗
40. Das A, Sivaprasad S, Chakraborti P, Tarafder S (2008) Correspondence of fracture surface features with mechanical properties in 304LN stainless steel. Mater Sci Eng A 496(1):98–10510.1016/j.msea.2008.05.007 ↗