Advanced Materials Research Vols 97-101 (2010) pp 158-161 Online: 2010-03-02

© (2010) Trans Tech Publications, Switzerland

doi:10.4028/www.scientific.net/AMR.97-101.158

Numerical Simulation on the Effect of Process Parameters for

Incremental Sheet Forming
Qin Qin1, a, Diping Wu1,b, Mi Li2,C and Yong Zang1,d
1
University of Science and Technology Beijing, No.30 Xueyuan Road, Beijing, 100083, China
2
Sinosteel Engineering Design & Research Institute Co., Ltd., Beijing, 100080, China
a
qinqin@me.ustb.edu.cn, bwudiping@me.ustb.edu.cn, cLimi_mi@163.com,
d
yzang@me.ustb.edu.cn

Keywords: Incremental sheetmetal Forming ， Finite element method, Simulation ， Process

parameter

Abstract. Incremental sheet forming (ISF), based on the ‘layered manufacturing’ principle of rapid
prototype manufacturing technology, is an innovative and highly flexible technology for forming
complex shaped parts without the need for costly dies. This paper presents a numerical investigation
on the influence of forming process parameters by modeling the forming process. ANSYS/LS-DYNA
has been used for the simulation. The results of study show that small vertical step size can improve
the accuracy of the forming. Moreover, large forming angle can increase plastic strain and the four
screwdown point optimization paths is an effective method to increase the accuracy of the formed
sheet.

Introduction
The incremental sheet forming process (ISF) involves the use of a smooth forming tool, which is
rotated and moved in 3D space against the work piece. This work piece is clamped around its
periphery in a holder on the machine bed and the movement of the tool is controlled by a CNC milling
machine. The force between the tool and the sheet metal work piece causes local plastic deformation,
enabling a 3-D profile to be made by progressively moving the tool against the work piece in a
controlled pattern. The ISF process avoids the need for expensive dies used in sheet forming process
because the only equipment necessary is a standard CNC milling machine with CAD/CAM software,
and a smooth forming tool. Therefore, it is possible in theory to move directly from a 3D CAD design
to make a finished product without any intermediate stages [1-3].
A number of academic groups around the world have made various studies of the process. Most
researchers have focused on the force measurement, applications and FEM process modelling the
deformation mechanism [3]. Work by the authors of this paper, focuses on the generation a tool path
correction algorithm for optimum process accuracy, but also aims to understand the influence of
forming process parameters using FEM modelling and experimental measurement. A FEM model
should then enable reliable theoretical predictions of process limitations and product profile.

Finite Element Modelling

A pyramid part with dimensions 160 mm× 210 mm for the top rectangle, 20mm depth and 45°slope
was chosen for the case study in this paper. A cylindrical forming tool with a 17.5mm diameter
spherical head was mounted on the vertical axis of the machine. The tool traversed along a path that
was controlled by the CNC machine. In this FEM model, the shell 163 element was used. The element
size used for the sheet was 2.5mm×2.5mm. The contact between the sheet and the tool was also
considered during this modelling. The mechanical behaviour of Aluminum 1050-0 was used to model
the sheet material’s behaviour for this paper[4,5].This renders the solution time excessively long such
that a rigid tool material, an artificially high tool velocity and mass scaling have been considered to

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 Advanced Materials Research Vols. 97-101 159

short it because the ISF process involves large deformations and long working times [6]. The whole
model consists of 5564 elements and 5732 nodes（Fig.1）.

1
ELEMENTS
JUL 14 2004
14:54:25

LS-DYNA user input

Fig.1 A 3D FEM model Fig.2 Comparison between the experiment

and simulation results

An identical pyramid part to that being simulated was made by experiment by generating an ISF
tool path and forming the part on a CNC machine. The comparison between the simulated and
corresponding measured profile is shown in figure2. As can be seen, in Fig.2, the simulated profile is
significantly closer to the experimental, with this reduction in step size that is 2mm per cycle.
Therefore, this FEM model was used to discuss the forming effect of the process parameters such as
vertical step size, forming angle and different tool path.

Influences of vertical step size

The vertical step size is the distance that the tool moves in depth direction of a part when this tool is
controlled by a CNC milling machine. It is one of the important factors influencing the forming. This
paper discussed the four different vertical step sizes that are 10mm, 4mm, 2mm and 1mm per cycle
when the tool is moved. The analysis results show that geometric accuracies of the part profiles are
close and their profiles are symmetrical about axis Z when the vertical step size is 2mm or 1mm per
cycle. But the geometric profiles of the part are some difference and their asymmetry about axis Z
increases when the vertical step size is 4mm or 10mm per cycle. However, it took approximately
twenty hours and fifty three minutes to complete the simulation when the vertical step size is 2mm. It
took approximately thirty sever hours and nine minutes to complete the simulation when the vertical
step size is 1mm. The solution time adds about 78%. Therefore, an appropriate vertical step size must
be chosen under the conditions prescribed by forming accuracies for reducing the solution time. The
thickness distribution of the formed part is shown in Fig. 3 and Fig.4.
thickness of the formed part(mm)

1.00

0.95

0.90

0.85

0.80

0.75
0 1 2 3 4 5 6 7 8 9 10 11

vertical step(mm)

Fig.3 The shell thickness distribution Fig.4 The minimum thickness

when vertical step is 2 mm under different vertical step
160 Manufacturing Science and Engineering I

As can be seen in Fig.3 and Fig.4, the thinning areas of the formed part occurs on the side wall of
the pyramid part and the minimum thickness takes place on the corner of this part. The minimum
thickness of the formed part increases when the vertical step decreases. The minimum thickness of the
part is 0.94mm when the vertical step is 4mm per cycle. The minimum thickness of the part adds up to
0.97mm when the vertical step decreases to 1mm.

Influences of forming angle

The forming angle is the angle between the side wall of the pyramid part after being formed and the
original horizon surface of the sheet. This angle also influences the strain and the thickness
distribution of the part. Work by the authors of this paper, discusses the different forming angles that
are 30°, 45°, 60° and 75° when the vertical step is 2mm per cycle. These simulation results are shown
in Fig.5 and Table 1.

Fig.5 The shell thickness of different Fig.6 Longitudinal section and symmetry
forming angles with the different paths

Table1 the von Mises stress and von Mises plastic strain of different forming angles
Forming angle [ ° ] 30 45 60 75
Maximum equivalent stress [ MPa ] 95.4 104 108 123
Maximum equivalent strain 0.322 0.602 0.938 1.279

As can be seen in Fig.5 and Table 1, the maximum equivalent stress and the maximum equivalent
strain of the formed sheet obviously enhance when the forming angle is increased. The ratios of these
maximum equivalent stresses are 1.28: 1.13: 1.09: 1 and the ratios of these maximum equivalent
strains are about 4: 3: 2: 1 when the forming angles are75°, 60°, 45° and 30°. The simulation results
also indicate that the minimum thickness of the sheet is 0.47 mm when the forming angle is 75° and
the minimum thickness of the sheet adds up to 1.21mm when the forming angle is 30°. The reason is
that the main deformation area is in the side wall for the pyramid part. Therefore, the area of the side
wall for the pyramid part decreases when the forming angle increases. Due to the same depth of the
part, the biggish deformation of the unit area causes the thickness of the shell to be reduced.

Influences of tool path

A reasonable tool path must be designed to increase the forming feasibility of the sheet and decrease
the defects of the formed part. At the same time, the appropriate screwdown points are also chosen
carefully during the design of the tool path. Work by the authors of this paper, focuses on the
generation a tool path correction algorithm for the choice of the different screwdown points, but also
aims to understand the geometric accuracies and the strain of the formed parts using this FEM model.
 Advanced Materials Research Vols. 97-101 161

In this paper, path 1 is designed to adopt one single point to screw at the same corner of the pyramid
part when the tool begins to move per cycle. Path 2 is designed to adopt two points to screw at the
diagonal corner of this part when the tool begins to move per cycle. Path 3 is designed to adopt four
points to screw at the all corner of this part when the tool begins to move per cycle. The simulation
results also indicate that the geometric accuracies of the formed part using path3 is better than that of
the formed part using other tool paths. And the symmetry of the part along z axis using path3 is
improved.
At the same time, the maximum equivalent strain of the formed part using path1 is 0.78 and the
maximum equivalent strain of the formed part using path2 is 0.736 and the maximum equivalent
strain of the formed part using path1 decrease to 0.635. The maximum equivalent strain of the part
using path 3 is compare with that of formed part using path1, this strain declines 18.6%.It means that
the forming limit of the sheet may be improved when the multi-point are used to screw down when the
tool begins to move per cycle.

Conclusions
The ISF process has been investigated when simulating a pyramid with a 45°wall slope using the
Finite Element Method. By using ANSYS/LS-DYNA, it is possible to model the ISF process such
that a better understanding of the deformation mechanism is achieved.
（1） Simulated results show good agreement with experimental data for the geometry of the
pyramid when the vertical step size is 2mm or 1mm per cycle. An appropriate vertical step
size must be chosen under the conditions prescribed by forming accuracies for reducing the
solution time.
（2） The maximum equivalent stress and the maximum equivalent strain of the formed sheet
obviously enhance when the forming angle is increased. Therefore, the small forming angle
can improve the limit of the sheet and increase the thickness of the formed part.
（3） The geometric accuracies of the formed part are improved when the four corner of the pyramid
part are adopted to screw down, then the maximum equivalent strains of the formed part are
decreased and the forming limit of the sheet may be improved.

Acknowledgements
The authors wish to thank the EPSRC’s Engineering IMRC at the University of Bath for supplying the
experimental results.

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Manufacturing Science and Engineering I
10.4028/www.scientific.net/AMR.97-101

Numerical Simulation on the Effect of Process Parameters for Incremental Sheet Forming
10.4028/www.scientific.net/AMR.97-101.158

DOI References
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doi:10.1016/S0007-8506(07)60680-5
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[4] Fratini, L. Ambrogio,G., Di Lorenzo, R., Filice,L. and Micari, F: Annals of CIRP, Vol.53 (2004), .207
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[5] Filice, L., Fantini, L., Micari, F: Annals of the CIRP, Vol. 51 (2002), p.199
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