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Simulation of a two-slope pyramid made by SPIF using an adaptive remeshing method with solid-shell finite element

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

Abstract

Single point incremental forming (SPIF) is an emerging application in sheet metal prototyping and small batch production, which enables dieless production of sheet metal parts. This research area has grown in the last years, both experimentally and numerically. However, numerical investigations into SPIF process need further improvement to predict the formed shape correctly and faster than current approaches. The current work aims the use of an adaptive remeshing technique, originally developed for shell and later extended to 3D “brick” elements, leading to a Reduced Enhanced Solid-Shell formulation. The CPU time reduction is a demanded request to perform the numerical simulations. A two-slope pyramid shape is used to carry out the numerical simulation and modelling. Its geometric difficulty on the numerical shape prediction and the through thickness stress behaviour are the main analysis targets in the present work. This work confirmed a significant CPU time reduction and an acceptable shape prediction accuracy using an adaptive remeshing method combined with the selected solid-shell element. The stress distribution in thickness direction revealed the occurrence of bending/unbending plus stretching and plastic deformation in regions far from the local deformation in the tool vicinity.

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Acknowledgments

The authors would like to gratefully acknowledge the support given by Portuguese Science Foundation (FCT) under the grant SFRH/BD/71269/2010 (J. I. V. Sena) and EXPL/EMS-TEC/0539/2013.

As Research director, A.M. Habraken would like to thank the Fund for Scientific Research (F.R.S - FNRS, Belgium) for its support.

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Authors and Affiliations

  1. GRIDS Research Group, TEMA Research Unity, Department of Mechanical Engineering, University of Aveiro, 3810, Aveiro, Portugal

    J. I. V. de Sena, R. A. F. Valente & R. J. Alves de Sousa

  2. Université de Liège, ArGEnCo Department, MS²F division, Chemin des Chevreuils 1, 4000, Liège, Belgium

    J. I. V. de Sena, C. F. Guzmán, L. Duchêne & A. M. Habraken

  3. Katholieke Universiteit Leuven, Department of Mechanical Engineering, Celestijnenlaan 300B, B-3001, Leuven, Belgium

    A. K. Behera & J. Duflou

Authors
  1. J. I. V. de Sena
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  2. C. F. Guzmán
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  3. L. Duchêne
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  4. A. M. Habraken
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  5. A. K. Behera
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  6. J. Duflou
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  7. R. A. F. Valente
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  8. R. J. Alves de Sousa
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Correspondence to J. I. V. de Sena.

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de Sena, J.I.V., Guzmán, C.F., Duchêne, L. et al. Simulation of a two-slope pyramid made by SPIF using an adaptive remeshing method with solid-shell finite element. Int J Mater Form 9, 383–394 (2016). https://doi.org/10.1007/s12289-014-1213-8

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  • DOI: https://doi.org/10.1007/s12289-014-1213-8

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