Skip to main content
SpringerLink
Log in

The significance of friction in the single point incremental forming process

  • Incremental forming: L. Filice
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

The Single Point Incremental Forming Process (SPIF) makes use of a single, small forming tool to incrementally deform a metal sheet into a complex shape. Without a need for dedicated tooling, this process meets the demand for small batch production and Rapid Prototyping of industrial shell-like structures. The sheet is formed due to a locally applied stress field on its surface, consisting of a normal and a shear component. The shear component is strongly influenced by friction with the dragging forming tool. In common practice, SPIF is performed under well lubricated conditions and with tool rotation, both designed to minimize friction. Through-Thickness Shear (TTS), which is part of the deformation mechanism in SPIF, may be intuitively linked to the friction applied during the process.

In this paper, the role of friction in SPIF is experimentally investigated through the forming of an aluminium alloy sheet (AA3103-O) into a large wall angle cone with and without imposed tool rotation. It is found that only the force component along the instantaneous tool movement direction depends on the tool rotation, i.e. on the friction conditions. Finite Element (FE) simulations are also presented, which use (i) continuum elements, so that TTS can be taken into account, (ii) a sub-millimetre FE mesh, so that the small contact zone may be adequately modelled, and (iii) a mixed isotropic-kinematic hardening law that captures the anisotropic hardening until large strains. Under these three conditions, a quite accurate prediction of the forming force is obtained. Furthermore, it is shown how the validation of the FE constitutive law may be decoupled from the validation of the FE contact model. Finally, it is seen that overall TTS predictions are affected by tool rotation, which shows that the deformation mechanism in SPIF may be controlled to a certain extent by the imposed tool rotation.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

References

  1. Jackson, K. and J. Allwood, The mechanics of incremental sheet forming. Journal of Materials Processing Technology, 2009. 209(3): p. 1158–1174.

    Article  Google Scholar 

  2. Eyckens, P., J. Del-lero Moreau, J. Duflou, A. Van Bael, and P. Van Houtte, MK Modelling of Sheet Formability in the Incremental Sheet Forming Process, Taking into Account Through-Thickness Shear. in ESAFORM 2009. UTwente, Netherlands.

  3. Eyckens, P., S. He, A. Van Bael, J. Duflou, and P. Van Houtte. Finite Element, Based Formability Predictions of Sheets Subjected to the Incremental Forming Process. in Proceedings of the 9th International Conference on Computational Plasticity. 2007. Barcelona: CIMNE.

  4. Aerens, R., P. Eyckens, A. Van Bael, and J. Duflou, Force prediction for single point incremental forming deduced from experimental and FEM observations. The International Journal of Advanced Manufacturing Technology, 2009, in press, http://dx.doi.org/10.1007/s00170-009-2160-2.

  5. Bouffioux, C., P. Eyckens, C. Henrard, R. Aerens, A. Van Bael, H. Sol, J.R. Duflou, and A.M. Habraken. Identification of material parameters to predict Single Point Incremental Forming forces. in ESAFORM 2008. Lyon, France.

  6. Bouffioux, C., C. Henrard, P. Eyckens, R. Aerens, A. Van Bael, H. Sol, J. Duflou, and A.M. Habraken. Comparison of the tests chosen for material parameter identification to predict single point incremental forming forces. in Proc of the IDDRG 2008 Int Conf. Olofström, Sweden.

  7. Henrard, C., C. Bouffioux, P. Eyckens, H. Sol, J. Duflou, P. Van Houtte, A. Van Bael, and A.M. Habraken, Forming Forces in Single Point Incremental Forming, Prediction by Finite Element Simulations, Validation and Sensitivity. submitted to Computational Mechanics, 2009.

  8. Jeswiet, J., F. Micari, G. Hirt, A. Bramley, J. Duflou, and J. Allwood, Asymmetric Single Point Incremental Forming of Sheet Metal. CIRP Annals - Manufacturing Technology, 2005. 54(2): p. 88–114.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department MTM, Faculty of Engineering, Katholieke Universiteit Leuven, Leuven, Belgium

    P. Eyckens, A. Van Bael & P. Van Houtte

  2. Mechanical Engineering Department, Katholieke Universiteit Leuven, Leuven, Belgium

    J. Duflou

  3. IWT, KHLim (Limburg Catholic University College), Campus Diepenbeek, Belgium

    A. Van Bael

  4. MTM, KULeuven, Kasteelpark Arenberg 44 -bus 2450, BE-3001, Heverlee, Belgium

    P. Eyckens

Authors
  1. P. Eyckens
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. Duflou
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Van Bael
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. P. Van Houtte
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. Eyckens.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Eyckens, P., Duflou, J., Van Bael, A. et al. The significance of friction in the single point incremental forming process. Int J Mater Form 3 (Suppl 1), 947–950 (2010). https://doi.org/10.1007/s12289-010-0925-7

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12289-010-0925-7

Keywords

Search

Navigation