Small-scale Finite Element Modelling of the Plastic Deformation Zone in the Incremental Forming Process

In this paper, the Finite Element submodelling technique is applied to model the small plastic zone in the Incremental Forming process with an adequately fine (sub-millimetre) mesh at a computationally acceptable cost. The focus lies on the distribution of the contact pressure between sheet and forming tool. Different forming conditions of truncated cones are considered. Results show that the contact consists of two distinguishable parts. The obtained insights can be applied in the physical modelling of forming forces, which allows improving part accuracy through compensation for the mechanical stiffness of the forming machine.