Abstract:
Incremental sheet forming (ISF) is an incredibly new flexible forming system. ISF
has first-rate adaptability to standard milling machines and requires minimum use of
complicated tooling, dies and forming press, which makes the process cost-effective and
smooth to automate for numerous applications. Incremental Sheet Forming (ISF) is an
advanced forming process used to obtain application specific, customized, symmetric or
asymmetric shapes that are required for automobile and aircraft industries for specific
purposes. Hemispherical tool used in this forming process consecutively forces the sheet to
deform locally and ultimately gives the target profile. Various machining parameters, like
forming feed, lubrication and step size are varied to get the best working parameters for the
incremental sheet forming. AA-5083 and AISI 1005 grade materials are used for comparison
and best results. After validating the Abaqus model with previous work, a material model
was ready for both materials. Mesh convergence was done with different element size. Blank
sheet is used as a deformable part and tool is used as an analytically rigid part. Hemispherical
tip tool used in this forming process consecutively forces the sheet to deform locally and
ultimately gives the target profile. Interaction between the tool and sheet is surface to surface
with kinematic constraint method. Three boundary conditions were used one for the sheet
and two for the tool. Finite element Simulations were done by varying the three process
parameters using explicit dynamic analysis and the results were observed. Output parameters
were Forming Force in z-axis (RF3), Total Strain energy (ALLIE), External work (ALLWK)
and Von Mises stress. Results shows that as the step size increases the forming force, energy
and stresses increases. When the feed increases the forming force and stresses decreases
whereas the energies increases. In the end, when coefficient of friction increases forming
force and stresses decreases. Experimentation will be done in near future to validate the
results.
