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Finite element simplifications and simulation reliability in single point incremental forming
ID Pepelnjak, Tomaž (Author), ID Sevšek, Luka (Author), ID Lužanin, Ognjan (Author), ID Milutinović, Mladomir (Author)

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Abstract
Single point incremental forming (SPIF) is one of the most promising technologies for the manufacturing of sheet metal prototypes and parts in small quantities. Similar to other forming processes, the design of the SPIF process is a demanding task. Nowadays, the design process is usually performed using numerical simulations and virtual models. The modelling of the SPIF process faces several challenges, including extremely long computational times caused by long tool paths and the complexity of the problem. Path determination is also a demanding task. This paper presents a finite element (FE) analysis of an incrementally formed truncated pyramid compared to experimental validation. Focus was placed on a possible simplification of the FE process modelling and its impact on the reliability of the results obtained, especially on the geometric accuracy of the part and bottom pillowing effect. The FE modelling of SPIF process was performed with the software ABAQUS, while the experiment was performed on a conventional milling machine. Low-carbon steel DC04 was used. The results confirm that by implementing mass scaling and/or time scaling, the required calculation time can be significantly reduced without substantially affecting the pillowing accuracy. An innovative artificial neural network (ANN) approach was selected to find the optimal values of mesh size and mass scaling in term of minimal bottom pillowing error. However, care should be taken when increasing the element size, as it has a significant impact on the pillow effect at the bottom of the formed part. In the range of selected mass scaling and element size, the smallest geometrical error regarding the experimental part was obtained by mass scaling of 19.01 and tool velocity of 16.49 m/s at the mesh size of 1 × 1 mm. The obtained results enable significant reduction of the computational time and can be applied in the future for other incrementally formed shapes as well.

Language:English
Keywords:single point incremental forming, numerical simulation, mass scaling, time scaling, pillow effect, artificial neural networks
Work type:Article
Typology:1.01 - Original Scientific Article
Organization:FS - Faculty of Mechanical Engineering
Publication status:Published
Publication version:Version of Record
Year:2022
Number of pages:22 str.
Numbering:Vol. 15, iss. 10, art. 3707
PID:20.500.12556/RUL-136983 This link opens in a new window
UDC:004.032.26:621.9
ISSN on article:1996-1944
DOI:10.3390/ma15103707 This link opens in a new window
COBISS.SI-ID:109389571 This link opens in a new window
Publication date in RUL:27.05.2022
Views:783
Downloads:140
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Record is a part of a journal

Title:Materials
Shortened title:Materials
Publisher:Molecular Diversity Preservation International
ISSN:1996-1944
COBISS.SI-ID:33588485 This link opens in a new window

Licences

License:CC BY 4.0, Creative Commons Attribution 4.0 International
Link:http://creativecommons.org/licenses/by/4.0/
Description:This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

Language:Slovenian
Keywords:enotočkovno inkrementalno preoblikovanje, numerična simulacija, skaliranje mase, skaliranje časa, efekt blazine, umetno nevronsko omrežje

Projects

Funder:ARRS - Slovenian Research Agency
Project number:P2-0248
Name:Inovativni izdelovalni sistemi in procesi

Funder:ARRS - Slovenian Research Agency
Project number:J2-2511
Name:Prilagodljivo utrjevanje površin avstenitnih jekel s procesi kriogenega preoblikovanja

Funder:Other - Other funder or multiple funders
Funding programme:Autonomous Province of Vojvodina, Provincial Secretariat for Higher Education and Scientific Research
Project number:142-451-2671/2021-01/02
Name:Collaborative systems in the digital industrial environment

Funder:Other - Other funder or multiple funders
Funding programme:CEEPUS
Project number:CII-HR-0108

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