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Strain evolution in the single point incremental forming process: digital image correlation measurement and finite element prediction

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Abstract

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.

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Notes

  1. The set named here “Mises-Swift” corresponds in [23] to “Set 1*”, “Hill-Swift” to “Set 1”, “Mises-AF” to “Set 5* Shell”, and “Hill-AF” to “Set 5 Shell”.

  2. In the pie-tip of the brick pie-model, wedge-shaped elements (6 nodes) of 1st order and with reduced integration are used.

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Acknowledgements

The authors from the Department of MTM at K.U.Leuven gratefully acknowledge the financial support from the Institute for the Promotion of Innovation by Science and Technology in Flanders (IWT) and from the Interuniversity Attraction Poles Program from the Belgian State through the Belgian Science Policy agency, contract IAP6/24. The authors from the department PMA at Katholieke Universiteit Leuven and MeMC at Vrije Universiteit Brussel gratefully acknowledge the financial support from the Institute for the Promotion of Innovation through Science and Technology in Flanders (IWT-Vlaanderen) and from the National Fund for Scientific Research, Belgium (F.W.O.). As research director, Anne Marie Habraken would like to thank the Fund for Research Scientific (FNRS, Belgium) for its support.

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Authors and Affiliations

  1. MTM, Katholieke Universiteit Leuven, Kasteelpark Arenberg 44, bus 2450, 3001, Heverlee, Belgium

    Philip Eyckens, Albert Van Bael & Paul Van Houtte

  2. MeMC, Vrije Universiteit Brussel, Pleinlaan 2, 1050, Elsene, Belgium

    Bachir Belkassem, Jun Gu & Hugo Sol

  3. Samtech, Liège Science Park, Rue des Chasseurs-Ardennais 8, 4031, Angleur, Belgium

    Christophe Henrard

  4. ArGEnCo Department, University of Liège, Allée des Chevreuils 1, 4000, Liège, Belgium

    Anne Marie Habraken

  5. PMA, Katholieke Universiteit Leuven, Celestijnenlaan 300 B, 3001, Heverlee, Belgium

    Joost R. Duflou

  6. IWT, KHLim (Limburg Catholic University College), Campus Diepenbeek, Agoralaan gebouw B, bus 3, 3590, Diepenbeek, Belgium

    Albert Van Bael

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  1. Philip Eyckens
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  2. Bachir Belkassem
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  4. Jun Gu
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  5. Hugo Sol
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  7. Joost R. Duflou
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  8. Albert Van Bael
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  9. Paul Van Houtte
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Correspondence to Philip Eyckens.

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Eyckens, P., Belkassem, B., Henrard, C. et al. Strain evolution in the single point incremental forming process: digital image correlation measurement and finite element prediction. Int J Mater Form 4, 55–71 (2011). https://doi.org/10.1007/s12289-010-0995-6

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  • DOI: https://doi.org/10.1007/s12289-010-0995-6

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