Numerical Simulation Of Sheet Metal Single Point Incremental Forming Process And Optimization Analysis

The part always with various types of defects during the process of single point incremental forming since the sheet experiences the complex change process of stress and strain. In order to improve quality and precision of product the forming mechanism of incremental forming need to be studied. Then technological parameters need to be selected rationally and the route of the tool need to be designed to optimize the design of incremental forming which avoid excessive reduction of thickness and broken of plate.The value of stress, strain and thickness of plate are calculated based on the theory of plastic mechanics. Finite element simulation processes of incremental forming are carried out based on ANASYS/LS-DYNA. The key problems of the numerical simulation such as: the select of the element and material are solved. Tool path and parameters are optimized based on the model. The result shows spiral feeding can improve the performance of sheet comparative with linear feed. The multi steps forming can get the parts with well-distributed thickness and get the parts with over-limit forming angle. Then the paper focused on investigation of the influence of tool head size, feed rate, forming angle and sheet thickness on the reduction of thinning and the thickness distribution. The results show forming angle, tool pitch and tool diameters are the main factors to forming thickness. Least-square response surface method is adopted to set up the approximate optimization model for thinning. The sequential quadratic programming is adopted to optimize approximation model. Process the automobile front fender with uniform distribution according to the optimization results.