The Influence of the Strain-Hardening Model in the Axial Force Prediction of Single Point Incremental Forming

Abstract

Estimation of the loading conditions during incremental sheet forming is important for designing dedicated equipment, safely utilizing adapted machinery, and developing online process control strategies or trajectory compensation for robot compliance. In this study, we investigate the forming force of pyramidal components of uniform wall angles through analytical, experimental, and numerical approaches. After reviewing the existing research, the accuracy of the estimations from two analytical models and finite element simulations was assessed. Experimental results revealed that the maximum force occurs at 45° and 60° for AA1050-H24 and AISI-SAE 304 materials, respectively. FEA simulations leveraging tensile test data and refined isotropic hardening laws provided conservative estimations for the two materials. In the case of the AA1050-H24, numerical models accurately reproduce the experimental trend of components formed with Single Point Incremental Forming (SPIF) at different wall angles. On the other hand, alternative hardening models may be required to improve the force predictions for the AISI-SAE 304 material.