The Effects of Forming Parameters on the Single Point Incremental Forming of 1050 Aluminum Alloy Sheet

The single point incremental forming (SPIF) is one of the dieless forming processes which is widely used in the sheet metal forming. The correct selection of the SPIF parameters influences the formability and quality of the product. In the present study, the Gurson-Tvergaard Needleman (GTN) damage model was used for the fracture prediction in the numerical simulation of the SPIF process of aluminum alloy 1050. The GTN parameters of AA 1050 sheet were firstly identified by the numerical simulation of tensile test and comparison of the experimental and numerical stress-strain curves. The identified parameters of the GTN damage model were used for fracture prediction in the SPIF process. The numerical results of the fracture position, thickness variation across the sample and forming height were compared with the experimental results. The numerical results had good agreement with the experimental ones. The effect of SPIF main parameters was investigated on the formability of samples by the verified numerical model. These parameters were tool rotation speed, tool feed rate, tool diameter, wall angle of the sample, vertical pitch, and friction between the tool and the blank.

Keywords:

Single point incremental forming (SPIF) , GTN damage model , Response surface method (RSM) , Fracture , Finite element method (FEM)