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See detailExperimental and numerical study of an AlMgSc sheet formed by an incremental process
Bouffioux, Chantal ULg; Lequesne, Cédric ULg; Vanhove, H. et al

in Journal of Materials Processing Technology (2011), 211(11), 1684-1693

A recently developed AlMgSc alloy is studied since this material, which is well adapted to the aeronautic domain, is poorly known. The first objective is to reach a better knowledge of this alloy to ... [more ▼]

A recently developed AlMgSc alloy is studied since this material, which is well adapted to the aeronautic domain, is poorly known. The first objective is to reach a better knowledge of this alloy to provide the missing useful information to the aeronautic industry and to help research institutes who want to simulate sheet forming processes by Finite Element (FE) simulations. A set of experimental tests has been performed on the as-received sheets, material laws have been chosen and the corresponding material parameters have been adjusted to correctly describe the material behaviour. The second objective is to study the applicability of the Single Point Incremental Forming process (SPIF) on this material. Truncated cones with different geometries were formed and the maximum forming angle was determined. A numerical model was developed and proved to be able to predict both the force evolution during the process and the final geometrical shape. Moreover, the model helps reaching a better understanding of the process. The characterisation method described in this research and applied on the AlMgSc alloy can be extended to other alloys. In addition, the numerical simplified model, able to accurately describe the SPIF process with a reduced computation time, can be used to study more complex geometries. [less ▲]

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See detailForming forces in single point incremental forming: prediction by finite element simulations, validation and sensitivity
Henrard, Christophe; Bouffioux, Chantal ULg; Eyckens, P. et al

in Computational Mechanics (2011), 47

The aim of this article is to study the accuracy of finite element simulations in predicting the tool force occurring during the single point incremental forming (SPIF) process. The forming of two cones ... [more ▼]

The aim of this article is to study the accuracy of finite element simulations in predicting the tool force occurring during the single point incremental forming (SPIF) process. The forming of two cones in soft aluminum was studied with two finite element (FE) codes and several constitutive laws (an elastic–plastic law coupled with various hardening models). The parameters of these laws were identified using several combinations of a tensile test, shear tests, and an inverse modeling approach taking into account a test similar to the incremental forming process. Comparisons between measured and predicted force values are performed. This article shows that three factors have an influence on force prediction: the type of finite element, the constitutive law and the identification procedure for the material parameters. In addition, it confirms that a detailed description of the behavior occurring across the thickness of the metal sheet is crucial for an accurate force prediction by FE simulations, even though a simple analytical formula could provide an otherwise acceptable answer. [less ▲]

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See detailStrain Evolution in the Single Point Incremental Forming Process: Digital Image Correlation Measurement and Finite Element Prediction
Eyckens, P.; Belkassem, B.; Henrard, Christophe et al

in International Journal of Material Forming (2011)

Incremental Sheet Forming (ISF) is a relatively new class of sheet forming processes that allow the manufacture of complex geometries based on computer-controlled forming tools in replacement (at least ... [more ▼]

Incremental Sheet Forming (ISF) is a relatively new class of sheet forming processes that allow the manufacture of complex geometries based on computer-controlled forming tools in replacement (at least partially) of dedicated tooling. This paper studies the straining behaviour in the Single Point Incremental Forming (SPIF) variant (in which no dedicated tooling at all is required), both on experimental basis using Digital Image Correlation (DIC) and on numerical basis by the Finite Element (FE) method. The aim of the paper is to increase understanding of the deformation mechanisms inherent to SPIF, which is an important issue for the understanding of the high formability observed in this process and also for future strategies to improve the geometrical accuracy. Two distinct large-strain FE formulations, based on shell and first-order reduced integration brick elements, are used to model the sheet during the SPIF processing into the form of a truncated cone. The prediction of the surface strains on the outer surface of the cone is compared to experimentally obtained strains using the DIC technique. It is emphasised that the strain history as calculated from the DIC displacement field depends on the scale of the strain definition. On the modelling side, it is shown that the mesh density in the FE models plays a similar role on the surface strain predictions. A good qualitative agreement has been obtained for the surface strain components. One significant exception has however been found, which concerns the circumferential strain evolution directly under the forming tool. The qualitative discrepancy is explained through a mechanism of through-thickness shear in the experiment, which is not fully captured by the present FE modelling since it shows a bending-dominant accommodation mechanism. The effect of different material constitutive behaviours on strain prediction has also been investigated, the parameters of which were determined by inverse modelling using a specially designed sheet forming test. Isotropic and anisotropic yield criteria are considered, combined with either isotropic or kinematic hardening. The adopted constitutive law has only a limited influence on the surface strains. Finally, the experimental surface strain evolution is compared between two cones with different forming parameters. It is concluded that the way the plastic zone under the forming tool accommodates the moving tool (i.e. by through-thickness shear or rather by bending) depends on the process parameters. The identification of the most determining forming parameter that controls the relative importance of either mechanism is an interesting topic for future research. [less ▲]

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See detailMulti-Step toolpath approach to overcome forming limitations in single point incremental forming
Verbert, J.; Belkassem, B.; Henrard, Christophe ULg et al

in Boisse, P. (Ed.) Proceedings of the 11th International ESAFORM Conference on Material Forming (2008)

Although Incremental Forming offers distinct advantages over traditional forming processes, such as short lead times and low setup costs, the process still has some drawbacks. Besides the obtainable ... [more ▼]

Although Incremental Forming offers distinct advantages over traditional forming processes, such as short lead times and low setup costs, the process still has some drawbacks. Besides the obtainable accuracy, one of the main challenges of the process are the process limits. Many workpiece geometries cannot be manufactured due to the fact that the maximum wall angle that can be formed is limited for a certain sheet material and thickness to a given angle. Different solutions to this approach have been proposed and this paper further investigates one of those solutions, the multi step approach for single point incremental forming. Experiments were performed and compared with simulations to better understand the phenomena underlying the improved process performance. [less ▲]

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See detailComparison of the tests chosen for material parameter identification to predict single point incremental forming forces
Bouffioux, Chantal ULg; Henrard, Christophe ULg; Eyckens, P. et al

in Asnafi, Nader (Ed.) Proceedings of the International Conference of International Deep Drawing Research Group (IDDRG 2008) (2008)

Single Point Incremental Forming is a sheet forming process that uses a smooth-ended tool following a specific tool path and thus eliminates the need for dedicated die sets. Using this method, the ... [more ▼]

Single Point Incremental Forming is a sheet forming process that uses a smooth-ended tool following a specific tool path and thus eliminates the need for dedicated die sets. Using this method, the material can reach a very high deformation level. A wide variety of shapes can be obtained without specific and costly equipment. To be able to optimize the process, a model and its material parameters are required. The inverse method has been used to provide material data by modeling experiments directly performed on a SPIF set-up and comparing them to the experimental measurements. The tests chosen for this study can generate heterogeneous stress and strain fields. They are performed with the production machine itself and are appropriate for the inverse method since their simulation times are not too high. [less ▲]

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