Assessing the influence of modeling choices on finite element analysis for robotic single-point incremental sheet forming
José CAICEDO, Sandra CHEVRET, Idriss TIBA, Yessine AYED, Tudor BALAN
Abstract. Single Point Incremental Forming (SPIF) is a flexible manufacturing process enabling the production of complex geometries without requiring dies. However, geometric deviations caused by tool compliance and sheet springback necessitate finite element analysis (FEA) to predict forming forces, material flow, and final geometry accurately, ensuring a comprehensive understanding of the process behavior. This study explores essential FEA modeling parameters and choices such as hardening laws, yield criteria, mesh density, element types, and friction coefficients. Material characterization experiments on AA5754-H111 facilitated the calibration of constitutive models, including Voce, Swift-Voce, and Chaboche, paired with Hill48 and von Mises yield criteria. Numerical simulations underscored the critical role of mesh refinement and element selection. Moreover, the friction coefficient exhibited minimal influence in isothermal simulations but demonstrated slightly greater importance under thermomechanical conditions. These findings underscore the need for a careful balance of parameter selection to enhance FEA accuracy while managing computational costs effectively.
Keywords
Single-Point Incremental Forming, FEA, Plasticity Modeling
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: José CAICEDO, Sandra CHEVRET, Idriss TIBA, Yessine AYED, Tudor BALAN, Assessing the influence of modeling choices on finite element analysis for robotic single-point incremental sheet forming, Materials Research Proceedings, Vol. 54, pp 1303-1312, 2025
DOI: https://doi.org/10.21741/9781644903599-142
The article was published as article 142 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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