Finite Element Analysis of Sheet Thickness and Force Variation in AA6063 During Single Point Incremental Forming
The single point incremental forming (SPIF) using aluminum alloy-based sheets is widely used in automobile and aerospace industries due to its high strength to weight ratio. SPIF is one of the evolving manufacturing processes due to its potential for die-less forming of metallic sheets. The maximum allowable formability of AA-6063 is limited to the elongation ranging from 12 to 30%. This process generally uses hemispherical end-shaped forming tool which traces the generated CNC code path to acquire the desired shape. In this study, a conical geometry is formed through experiments and simulations using SPIF. This study presents a comparative finite element analysis (FEA) between implicit- and explicit-based computational techniques for SPIF using Abaqus®. In this study, output responses include sheet thickness variation, Von-Mises stress distribution, fracture limit curve and solver time for each computational method. Implicit computational method proves its advantages over explicit for accuracy.
KeywordsSPIF FEA Tool path Explicit and implicit computational method ABAQUS
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