LAPSE:2023.36234
Published Article
LAPSE:2023.36234
A Mathematical Model for Force Prediction in Single Point Incremental Sheet Forming with Validation by Experiments and Simulation
Ravi Prakash Singh, Santosh Kumar, Pankaj Kumar Singh, Md. Meraz, Ashutosh Kumar Srivastwa, Sachin Salunkhe, H. M. A. Hussein, Emad S. Abouel Nasr, Ali Kamrani
July 7, 2023
Incremental sheet forming (ISF) is an emerging technology that has shown great potential in forming customized three-dimensional (3D) parts without the use of product-specific dies. The forming force is reduced in ISF due to the localized nature of deformation and successive forming. Forming force plays an important role in modeling the process accurately, so it needs to be evaluated accurately. Some attempts have been made earlier to calculate the forming force; however, they are mostly limited to empirical formulae for evaluating the average forming force and its different components. The current work presents a mathematical model for force prediction during ISF in a 3D polar coordinate system. The model can be used to predict forces for axis-symmetric cones of different wall angles and also for incremental hole flanging. Axial force component, resultant force in the r-θ plane, and total force have been calculated using the developed mathematical model appearing at different forming depths. The cone with the same geometrical parameters and experimental conditions was modeled and simulated on ABAQUS, and finally, experiments were carried out using a six-axis industrial robot. The mathematical model can be used to calculate forces for any wall angle, but for comparison purposes, a 45° wall angle cone has been used for analytical, numerical, and experimental validation. The total force calculated from the mathematical model had a very high level of accuracy with the force measured experimentally, and the maximum error was 4.25%. The result obtained from the FEA model also had a good level of accuracy for calculating total force, and the maximum error was 4.89%.
Keywords
contact area, finite element model, forming forces, forming limit diagram, incremental sheet forming
Suggested Citation
Singh RP, Kumar S, Singh PK, Meraz M, Srivastwa AK, Salunkhe S, Hussein HMA, Nasr ESA, Kamrani A. A Mathematical Model for Force Prediction in Single Point Incremental Sheet Forming with Validation by Experiments and Simulation. (2023). LAPSE:2023.36234
Author Affiliations
Singh RP: Indian Institute of Technology (BHU), Varanasi 221005, Uttar Pradesh, India [ORCID]
Kumar S: Indian Institute of Technology (BHU), Varanasi 221005, Uttar Pradesh, India
Singh PK: Indian Institute of Technology (BHU), Varanasi 221005, Uttar Pradesh, India [ORCID]
Meraz M: Indian Institute of Technology (BHU), Varanasi 221005, Uttar Pradesh, India [ORCID]
Srivastwa AK: Indian Institute of Technology (BHU), Varanasi 221005, Uttar Pradesh, India
Salunkhe S: Department of Mechanical Engineering, Vel Tech Rangarajan Sagunthala R & D Institute of Science and Technology, Avadi 600062, Tamil Nadu, India [ORCID]
Hussein HMA: Mechanical Engineering Department, Faculty of Engineering, Helwan University, Cairo 11732, Egypt [ORCID]
Nasr ESA: Department of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh 11421, Saudi Arabia [ORCID]
Kamrani A: Industrial Engineering Department, College of Engineering, University of Houston, Houston, TX 77204, USA
Journal Name
Processes
Volume
11
Issue
6
First Page
1688
Year
2023
Publication Date
2023-06-01
Published Version
ISSN
2227-9717
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Original Submission
Other Meta
PII: pr11061688, Publication Type: Journal Article
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LAPSE:2023.36234
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doi:10.3390/pr11061688
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Jul 7, 2023
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Jul 7, 2023
 
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Calvin Tsay
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