Simplified numerical approach for incremental sheet metal forming process

• A simplified FE model called “ISF-SAM” was developed to simulate the ISF process.
• The ISF-SAM is sufficiently accurate and quite efficient in terms of CPU time.
• A shell element, taking into account membrane and bending effects, has been used.
• A simplified contact algorithm is developed to manage the contact.
• A good correlation has been shown between the experimental and numerical results.

The current work presents a finite element approach for numerical simulation of the incremental sheet metal forming (ISF) process, called here “ISF-SAM” (for ISF-Simplified Analysis Modelling). The main goal of the study is to develop a simplified FE model sufficiently accurate to simulate the ISF process and quite efficient in terms of CPU time. Some assumptions have been adopted regarding the constitutive strains/stresses equations and the tool/sheet contact conditions. A simplified contact procedure was proposed to predict nodes in contact with the tool and to estimate their imposed displacements. A Discrete Kirchhoff Triangle shell element called DKT12, taking into account membrane and bending effects, has been used to mesh the sheet. An elasto-plastic constitutive model with isotropic hardening behaviour and a static scheme have been adopted to solve the nonlinear equilibrium equations. Satisfactory results have been obtained on two applications and a good correlation has been shown compared to experimental and numerical results, and at the same time a reduction of CPU time more than 60% has been observed. The bending phenomenon studied through the second application and the obtained results show the reliability of the DKT12 element.