Abstract
Beads are typical offset features used in sheet metal parts for increased out-of-plane bending stiffness. Incrementally forming beads using common tools presents a new paradigm for manufacturing versatility and geometrical flexibility in part design while bringing significant cost benefits for low volume applications in automotive and other industries. However, the production applications of incremental beading can be limited due to beading induced distortion and subsequent dimensional quality concerns. In this study, distortion reduction solutions are sought after based on a combined approach of virtual simulations and physical testing. Numerical models, through Finite Element Analysis, are developed to virtually describe the incremental beading process and predict the resultant distortion with the goal of improving model accuracy and reducing computational cost. The developed FEM models are validated against experimental data to serve as the basis for future virtual process optimization. Experimental approaches to effectively reduce distortion are identified during model validations. Effects of process variables are discussed.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Similar content being viewed by others
References
Bowen, D.T., Russo, I.M., Cleaver, C.J., Allwood, J.M., Loukaides, E.G.: From art to part: learning from the traditional smith in developing flexible sheet metal forming processes. J. Mater. Process. Technol. 299, 117337 (2022). https://doi.org/10.1016/j.jmatprotec.2021.117337
Yang, D.Y., et al.: Flexibility in metal forming. CIRP Ann. 67, 743–765 (2018). https://doi.org/10.1016/j.cirp.2018.05.004
Duflou, J.R., et al.: Single point incremental forming: state-of-the-art and prospects. Int.J. Mater. Form. 11(6), 743–773 (2017). https://doi.org/10.1007/s12289-017-1387-y
Peng, W., Ou, H., Becker, A.: Double-sided incremental forming: a review. J. Manuf. Sci. Eng. 141 (2019). https://doi.org/10.1115/1.4043173
Yanagimoto, J., Banabic, D., Banu, M., Madej, L.: Simulation of metal forming – visualization of invisible phenomena in the digital era. CIRP Ann. 71, 599–622 (2022). https://doi.org/10.1016/j.cirp.2022.05.007
Hou, Y., Min, J., Lin, J., Liu, Z., Carsley, J.E., Stoughton, T.B.: Springback prediction of sheet metals using improved material models. Procedia Eng. 207, 173–178 (2017). https://doi.org/10.1016/j.proeng.2017.10.757
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Suarez, D., Huang, L., Wang, Hp., Solomon, J., Sigmund, N., Cao, J. (2024). Distortion Reduction in Incremental Beading. In: Mocellin, K., Bouchard, PO., Bigot, R., Balan, T. (eds) Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity. ICTP 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-41023-9_68
Download citation
DOI: https://doi.org/10.1007/978-3-031-41023-9_68
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-41022-2
Online ISBN: 978-3-031-41023-9
eBook Packages: EngineeringEngineering (R0)