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Optimization of relative tool position in accumulative double sided incremental forming using finite element analysis and model bias correction

  • Thematic Issue: Flexible forming - Incremental Sheet Forming & Roll Forming
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

Double-Sided Incremental Forming (DSIF) uses two small, independently moving, hemispherical tools on either side of the sheet to form a desired shape by following a predefined tool path. This study was motivated by the observation that the relative tool position of the tools, specified in the tool path generation algorithm, affects the formed geometric accuracy. A methodology for defining the relative tool positioning in the tool path generation algorithm based on local part geometry is proposed using simplified Finite Element Analysis (FEA) and sample physical experiments combined with Gaussian Process modeling techniques. This approach can take into account the mechanics of deformation in DSIF explicitly and physical compliance of the DSIF machine implicitly. Physical experiments were performed to demonstrate the effectiveness of the proposed framework.

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Abbreviations

D:

the in-plane distance between the two tool axes

S:

distance from top of bottom to bottom of the sheet

Δz :

incremental depth

θ desired :

desired wall angle

θ formed :

formed wall angle

r t :

radius of top tool

r b :

radius of bottom tool

t0 :

initial sheet thickness

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Acknowledgments

The authors would like to acknowledge the National Science Foundation and Department of Energy, USA DE-EE0005764 for their support.

Disclaimer

This work was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government, nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. Any findings, opinions, and conclusions or recommendations expressed in this report are those of the authors and do not necessarily reflect those of the United States Government or any agency thereof.

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Authors and Affiliations

  1. Northwestern University, 2145 Sheridan Road, Evanston, IL, USA

    Ebot Ndip-Agbor, Jacob Smith, Huaqing Ren, Zhen Jiang, Jiachen Xu, Newell Moser, Wei Chen & Jian Cao

  2. Ford Motor Company, Dearborn, MI, USA

    Z. Cedric Xia

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  1. Ebot Ndip-Agbor
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  2. Jacob Smith
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  4. Zhen Jiang
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  7. Wei Chen
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  8. Z. Cedric Xia
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  9. Jian Cao
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Correspondence to Jian Cao.

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Ndip-Agbor, E., Smith, J., Ren, H. et al. Optimization of relative tool position in accumulative double sided incremental forming using finite element analysis and model bias correction. Int J Mater Form 9, 371–382 (2016). https://doi.org/10.1007/s12289-014-1209-4

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  • DOI: https://doi.org/10.1007/s12289-014-1209-4

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