Formation mechanism and modeling of surface waviness in incremental sheet forming

doi:10.1007/s11465-022-0679-1

Front. Mech. Eng.

2022, Vol. 17

Issue (2) : 23 https://doi.org/10.1007/s11465-022-0679-1

RESEARCH ARTICLE

Formation mechanism and modeling of surface waviness in incremental sheet forming

Kai HAN^1,², Xiaoqiang LI¹, Yanle LI^3,⁴(

), Peng XU¹, Yong LI¹, Qing LI⁵, Dongsheng LI¹

¹. School of Mechanical Engineering and Automation, Beihang University, Beijing 100083, China
². Beijing Institute of Aeronautical Materials, Beijing 100095, China
³. School of Mechanical Engineering, Shandong University, Jinan 250061, China
⁴. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, Jinan 250061, China
⁵. Materials Science Branch of Chinalco Research Institute, Chinalco Materials Application Research Institute Co., Ltd., Beijing 102209, China

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Abstract

Improving and controlling surface quality has always been a challenge for incremental sheet forming (ISF), whereas the generation mechanism of waviness surface is still unknown, which impedes the widely application of ISF in the industrial field. In this paper, the formation mechanism and the prediction of waviness are both investigated through experiments, numerical simulation, and theoretical analysis. Based on a verified finite element model, the waviness topography is predicted numerically for the first time, and its generation is attributed to the residual bending deformation through deformation history analysis. For more efficient engineering application, a theoretical model for waviness height is proposed based on the generation mechanism, using a modified strain function considering deformation modes. This work is favorable for the perfection of formation mechanism and control of surface quality in ISF.

Keywords surface waviness incremental sheet forming numerical simulation formation mechanism deformation history

Corresponding Author(s): Yanle LI

About author:

Tongcan Cui and Yizhe Hou contributed equally to this work.

Just Accepted Date: 22 April 2022 Issue Date: 20 July 2022

Cite this article:

Kai HAN,Xiaoqiang LI,Yanle LI, et al. Formation mechanism and modeling of surface waviness in incremental sheet forming[J]. Front. Mech. Eng., 2022, 17(2): 23.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-022-0679-1
https://academic.hep.com.cn/fme/EN/Y2022/V17/I2/23

Fig.1 Illustration of contact surface topography. Reprinted with permission from Ref. [12] from Elsevier.

Fig.2 Experimental setup: (a) dimensions of truncated pyramid specimen and (b) scheme of the forming process.

Fig.3 Partial FE model for the inclined wall of truncated pyramids.

Tab.1 Mechanical properties AA2024-O aluminum alloy. Reprinted with permission from Ref. [42] from Elsevier

$σ 0$	K	n	F	G	H	N
61.83 MPa	192.67 MPa	0.28	0.56	0.58	0.42	2.99

Tab.2 Material coefficients of Ludwik constitutive and Hill48 yield functions. Reprinted with permission from Ref. [42] from Elsevier

No.	V/( $mm ? s − 1$ )	$F n$ /N	$F dcf$ /N	$μ$
1	10	499.99	125.88	0.13
2	10	999.81	307.34	0.15
3	10	1499.05	395.10	0.13
4	20	1001.26	241.12	0.12
5	30	999.48	240.20	0.12

Tab.3 Experimental result of friction coefficients with various parameters

Fig.4 Stress states analysis of the cross-section in ISF.

Fig.5 Verifications of FE models: (a) comparison of geometrical profiles and thickness distributions between the experimental and simulation results; (b) comparison of the max principal strain between partial models (PM) and full model (FM).

Fig.6 Surface topography results: (a) experimental results; (b) simulation results; (c) comparison of surface profiles in the cross-section.

Fig.7 Average normal strain of selected elements.

Fig.8 Strain history of different thickness layers and illustration of deformation stages.

Fig.9 Experimental surface topography of different stages: (a) initial sheet, (b) Stage 1, (c) Stage 2, and (d) Stage 3.

Fig.10 Detailed description of Stage 3: (a) illustration of intermediate moments; (b) thickness strain states with different moments; (c) strain difference at different regions; and (d) illustration of “local bulge”.

$α$ /rad	$α f$ /rad	$α c$ /rad
π/6	0.51	0.64
π/4	0.74	0.83
π/3	0.98	1.09

Tab.4 Strain distribution coefficients of actual forming angle and contacting angle obtained from simulation results

Fig.11 The verification of strain model based on numerical strain distributions (US: uppermost surface; LS: lowest surface; SD: strain difference): (a) comparison between modified model (MBS) and traditional model (BS) at different surfaces; verification of strain model with different (b) process parameters (at forming angle of 45°), (c) sheet thicknesses, and (d) forming angles (at step size of 1.0 mm and tool radius of 10 mm).

Fig.12 Establishment of theoretical waviness model based on force balance.

Fig.13 Surface topography with different process parameters.

Fig.14 Results of theoretical model: (a) variation of theoretical waviness height based on experimental results; (b) contact stress of different tool radii.

Abbreviations
BS	Bending and stretching strain model
FE	Finite element
FM	Full model
ISF	Incremental sheet forming
MBS	Modified bending and stretching strain model
PM	Partial model
TPISF	Two-point incremental sheet forming
Variables
F, G, H, Q,M, and N	Material coefficients of Hill48 yield function
$F A$ , $F B$ , $F C$	Tangential forces per unit width in Regions A, B, and C, respectively
$F d c f$	Tension force in friction experiment
$F f$	Frictional force in friction experiment
$F n$	Compressive force in friction experiment
$H w$	Waviness height
$K$	Material coefficient of Ludwik constitutive function
$l$	Forming depth
L	Width size of partial FE model
n	Material hardening index of Ludwik constitutive function
r	Distance to the spherical centre
R	Tool radius
$R z$	Surface roughness of maximum peak to valley height
sz	Step size
$t 0$	Initial sheet thickness
V	Feed rate in friction experiment
$α$	Forming angle
$α f$	Actual contacting angle
$α t$	Actual forming angle after incremental forming
$β$	Residual forming angle
$σ 0$	Yield stress
$σ t a n$ , $σ c i r$ , $σ t h i$	Normal stresses in tangential, circumferential, and thickness directions, respectively
$σ tan A$ , $σ t h i A$	Tangential stress and thickness stress at Region A, respectively
$σ tan B$ , $σ t h i B$	Tangential stress and thickness stress at Region B, respectively
$σ t h i, r = R B$	Contact stress along the thickness direction at Region B
$σ x x$ , $σ y y$ , $σ z z$	Normal stresses along the X (rolling direction), Y (transverse direction), and Z (thickness direction) directions, respectively
$σ ¯$	Equivalent stress
$φ$	Current forming angle
$d ϕ$	Increment of tangential length
$d θ$	Increment of circumference width
$ε B, B S$ , $ε S, B S$	Bending strain and stretching strain in a bending and stretching strain model, respectively
$ε B, M B S$ , $ε S, M B S$ ,	Bending strain and stretching strain in MBS, respectively
$ε m a x P M$ , $ε m a x F M$	Max principal strain of partial and full model at specific forming depth of $l$ , respectively
$ε p$	Predeformation strain
$ε t a n$ , $ε c i r$ , $ε t h i$	Normal strains in the tangential, circumference, and thickness directions, respectively
$ε tan, B S$	Tangential strain evolution in BS
$ε tan, M B S$	Tangential strain evolution in MBS
$ε x x$ , $ε y y$ , $ε z z$	Normal strain along rolling direction, transverse direction and thickness direction, respectively
$ε ¯$	Equivalent strain
$μ$	Friction coefficient
$δ i$	Strain error

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