Tool Path Optimization And Numerical Simulation For Surface Parts On Single Point Incremental Forming

Single point incremental forming?SPIF?is a novel sheet metal forming process,which has been put forward in the 1990 s.However,SPIF has not been widely used in an industrial context due to some still existing forming drawbacks.As the forming angle is constantly changing,forming problems,such as poor surface quality,insufficient formation of flat area,large dimension error and low efficiency,are existed when surface parts are formed with constant step size ?z,which can not be adjusted with the change of forming angle on metal sheet single point incremental forming.This paper is mainly focused on the forming problems of surface parts.Two methods of tool path optimization were proposed:Method based on constant ?? increment and Method based on constant S₀ increment,the feasibility of these two optimization methods were verified by experiments.Numerical simulations were also developed to analyze the affect of process parameters on formability of surface parts based on ANSYS/Workbench finite element software.The main research contents are as follows:1)The main forming defects and their reasons of the surface parts were summarized.It was found that these defects are all related to the step size ?z.2)The experimental results show that the two optimization methods can not only improve the formed quality of surface parts,but also improve the forming efficiency significantly,compared with the the traditional method.3)The simulation results show that :The two optimization methods can improve the thickness thinning of the surface flat area,the smaller ?? or S₀ is,the more obvious the improvement.The forming accuracy of the surface flat area was improved obviously and it has little relation with the value of ?? or S₀.The optimization methods can change the stress distribution of the surface part and increase the strain of the metal plate,the max strain value tend to be the same regardless of the value of ?? or S₀.