Simulation of incremental sheet metal forming for making U-channel in two light-weight alloys

Simulation of incremental sheet metal forming for making U-channel in two light-weight alloys

BHUSHAN Bharat, RAMKUMAR Janakarajan, DIXIT Uday Shanker

Abstract. Incremental sheet metal forming (ISMF) is a viable method for fabricating complicated three-dimensional structures from sheet metal. It is characterized by localized deformation and is effective for both rapid prototyping and low-volume manufacturing. ISMF technology is suitable for quick product development time with affordable tooling and for deforming difficult-to-form materials. Simulation of the process reduces costly hit-and-trial attempts for manufacturing an accurate product. This article presents the simulation for producing a U-channel made of aluminum (Al 6061-T6) and titanium (Ti-6Al-4V) alloys. A finite element method (FEM) package, ABAQUS®, has been used for simulation using shell elements. The effect of various parameters on the forming forces is discussed using two different tools, flat and hemispherical-end.

Keywords
Incremental Sheet Metal Forming, Finite Element Method, U-Channel, Shell Element

Published online 4/19/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: BHUSHAN Bharat, RAMKUMAR Janakarajan, DIXIT Uday Shanker, Simulation of incremental sheet metal forming for making U-channel in two light-weight alloys, Materials Research Proceedings, Vol. 28, pp 1037-1046, 2023

DOI: https://doi.org/10.21741/9781644902479-114

The article was published as article 114 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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