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Investigation of Residual Stresses Induced by Incremental Sheet Forming and Stamping in Aluminum Alloys

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Abstract

Residual stresses induced during forming process are one of the key parameters that influence springback behavior and mechanical properties of formed sheet metal products. However, there is a limited understanding of the residual stresses present in parts formed by single-point incremental sheet forming (ISF) process. In the current research, an in-depth understanding of the residual stress distribution is developed through experimental characterizations and numerical simulation for ISF, and only numerical analysis was performed for stamping process. AA2024 square-truncated-pyramidal parts with three distinct geometrical characteristics are investigated to elucidate their effects on part qualities with respect to the competing forming processes, i.e., ISF and stamping. Residual stresses, part wall thinning and part deviation generated in ISF process are compared with its counterpart stamping process. It was revealed that the residual stresses induced by ISF process are mostly tensile on the inner surface and compressive on the outer surface of the sheet in all formed geometries. However, a transition of residual stress state from tensile to compressive and vice versa is observed for the stamping process. The magnitude of residual stresses generated in ISF formed parts is relatively high as compared to those from the stamping process due to localized hardening. The fundamental understanding of residual stresses developed in this study could be useful to improve dimensional accuracy and mechanical performance of sheet metal products in industrial applications.

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Acknowledgments

This work is fully funded by Agency for Science, Technology and Research (A*STAR), Singapore, under an industry alignment funding scheme: AME_IAF-PP_A1896a0034. D. Kumar also would like to thank Akshay Chaudhary from NUS and Wong Wei Hin Mark from IHPC for their scientific discussions during this project.

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Authors and Affiliations

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

    Dharmesh Kumar & Suwat Jirathearanat

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

    Liu Zhigang

  3. Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore

    A. Senthil Kumar

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  1. Dharmesh Kumar
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  2. Liu Zhigang
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Correspondence to Dharmesh Kumar.

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Kumar, D., Zhigang, L., Jirathearanat, S. et al. Investigation of Residual Stresses Induced by Incremental Sheet Forming and Stamping in Aluminum Alloys. J. of Materi Eng and Perform 32, 2950–2962 (2023). https://doi.org/10.1007/s11665-022-07304-3

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  • DOI: https://doi.org/10.1007/s11665-022-07304-3

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