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Change in geometry size and thinning rate in single-point incremental forming process of TA1 sheet: evaluation method and finite element analysis

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Abstract

As a mold-less forming technology of sheet materials, single-point incremental forming (SPIF) can efficiently and economically fabricate various protypes and products. Although considerable studies have been conducted on SPIF, further improvement is possible in terms of the analysis method of the forming part quality, such as the accuracy and simplicity of the method. In view of this, this study aimed at establishing a thinning rate evaluation method from a three-dimensional perspective. By taking a titanium alloy sheet as an example, the three-dimensional change in the part size and its thinning rate during the SPIF process were systematically investigated. Furthermore, LS-DYNA software was employed to simulate the forming process. The results showed that the proposed method can effectively evaluate the dimensional changes of any cross-section of the sheet material. With the use of finite element model, a better thinning behavior prediction of the as-formed TA1 titanium sheets was achieved. The finite element simulation results were well comparable to those of the actual forming process. The simulated deformation of the four corners of a square box during the forming process could reach a maximum value of 0.252 mm, which was close to the experimental result of 0.248 mm. The deformation depth from the finite element simulations was 9.01 mm, whereas the actual experimental result was 8.50 mm. This study provided some insight on the development of a forming quality evaluation method and the forming simulation of SPIF.

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Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

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Funding

This research received financial support from the Sichuan Science and Technology Program (Grant Nos. 2022YFG0366 and 2018G120037) and “Young Scholars” Program of Xihua University (Z202075). This research also funded Qiang Fang and Gang Chen.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Xihua University, Chengdu, 610039, China

    Haifeng Huang, Mingze Yue, Qifeng Tang, Biyou Peng & Gang Chen

  2. Chengdu Advanced Metal Materials Industry Technology Research Institute Co., Ltd., Chengdu, 610039, China

    Xinxin Tang

  3. Panzhihua Iron and Steel Research Institute, Panzhihua, 617000, China

    Qiang Fang

Authors
  1. Haifeng Huang
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  2. Mingze Yue
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  4. Biyou Peng
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  7. Gang Chen
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Contributions

All the authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Haifeng Huang and Mingze Yue. The first draft of the manuscript was written by Haifeng Huang and Gang Chen, and all the authors commented on the previous versions of the manuscript. All the authors read and approved the final manuscript.

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Correspondence to Biyou Peng, Xinxin Tang, Qiang Fang or Gang Chen.

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Huang, H., Yue, M., Tang, Q. et al. Change in geometry size and thinning rate in single-point incremental forming process of TA1 sheet: evaluation method and finite element analysis. Int J Adv Manuf Technol 125, 2743–2758 (2023). https://doi.org/10.1007/s00170-023-10935-y

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