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A multiple-tool method for fast FEM simulation of incremental sheet forming process

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Abstract

In this paper, we proposed a multiple-tool (MT) modeling method to reduce computational time for finite element simulations of incremental sheet forming (ISF) process. The aim is to investigate the computation efficiency and prediction accuracy of thickness reduction and springback of ISF parts using the MT simulation model. The toolpaths required for this method are generated by an in-house code and can be extended to accommodate complex ISF parts geometries. We found that the proposed MT method can significantly reduce CPU time and maintain geometric accuracy in tolerance, although the proposed MT simulation model is physically different from the real forming process of single-tool ISF. To validate the proposed method, the simulation results of the ISF with truncated cone geometry were compared with the experimental results in terms of thickness distribution, forming force, and springback. The comparison results show that the developed multi-tool simulation approach can reduce the CPU time by up to 90% with satisfactory geometric accuracy as compared to traditional FE model. We further designed an asymmetrical ISF parts with multiple curvature changes to verify the adaptability of the MT simulation method. The comparison results show that the method proposed in this study can also greatly reduce the CPU time while maintaining relatively high geometric accuracy for complex ISF part. This study provides an important guideline for the use of FE simulation in the design and fabrication of large industrial-scale ISF parts.

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Acknowledgements

The support of this work by the Institute of High Performance Computing (IHPC) and Singapore Institute of Manufacturing Technology (SIMTech), A*STAR is gratefully acknowledged.

Funding

This work is supported by the Institute of High Performance Computing (IHPC) and Singapore Institute of Manufacturing Technology (SIMTech), A*STAR.

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Authors and Affiliations

  1. Institute of High Performance Computing (IHPC), Agency for Science, Technology and Research (A*STAR), Singapore, Singapore

    Zhigang Liu & Wei Hin Wong

  2. Singapore Institute of Manufacturing Technology (SIMTech), Agency for Science, Technology and Research (A*STAR), Singapore, Singapore

    Dharmesh Kumar & Suwat Jirathearanat

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  1. Zhigang Liu
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  2. Dharmesh Kumar
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  3. Suwat Jirathearanat
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  4. Wei Hin Wong
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Contributions

Liu Zhigang conceived the modeling and analysis and wrote the manuscript.

Dharmesh Kumar and Jirathearanat Suwat conducted the experiment and data analysis.

Wong Wei Hin supervised this work and analyzed the data.

All authors involved in discussion and revised the manuscript.

Corresponding author

Correspondence to Zhigang Liu.

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Liu, Z., Kumar, D., Jirathearanat, S. et al. A multiple-tool method for fast FEM simulation of incremental sheet forming process. Int J Adv Manuf Technol 128, 4311–4329 (2023). https://doi.org/10.1007/s00170-023-12153-y

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