A fully parametric toolbox for the simulation of single point incremental sheet forming process: Numerical feasibility and experimental validation

Single point incremental forming (SPIF) is a sheet metal forming process that allows manufacturing components without the development of complex tools in comparison with stamping process.This work is dedicated to the development of SPIF for microparts (shape or detail) and for thin metal sheets (less than 1 mm). This paper focuses on the definition of a numerical toolbox to simulate this process at these scales. Forming of a pyramidal shape of 4 mm in height from a copper sheet with an initial thickness of 0.21 mm is suggested. The complete methodology is proposed and numerical results are presented in terms of global geometry (shape and section profiles), thickness evolution and forming forces. Equivalent experimental tests are carried out to validate the numerical approach. Different ways of evolution are provided at the end of this work.

► Toolbox for parametric simulation of incremental forming process. ► Automatic and parametric mesher. ► Simulations of micro-incremental sheet forming by FE method (MPP simulations). ► Post-processing toolbox. ► Numerical and experimental comparisons.