A finite element simulation of the incremental sheet forming process: a new method for G-code implementation

During the incremental sheet forming process, tool paths are generated by CAM software. The obtained files have several possible formats such as the APT or the G-code ones which can be directly transferred to CNC machines for parts forming. However, when it comes to the process simulation, the G-code format could not be used in common finite element programs. In this paper, a new method is developed to implement the G-code into the FE software Abaqus using the Python programming language. The G-code commands are translated into appropriate boundary conditions describing the exact forming tool motions without any decomposition or modification. The numerical results obtained by the proposed method and the conventional tool path decomposition method are compared in terms of the part shape, thickness distribution, forces evolution, and CPU times as well. On the other hand, a comparison of the surface roughness of two conical parts formed using these two formats has been conducted in order to investigate the potential effect of the tool path decomposition on surface quality.