Numerical Studies and Equipment Development for Single Point Incremental Forming

This paper summarizes the achievements obtained so far in the context of a research project carried out at the University of Aveiro, Portugal on both numerical and experimental viewpoints concerning Single Point Incremental Forming (SPIF). On the experimental side, the general guidelines on the development of a new SPIF machine are detailed. The innovation features are related to the choice of a six-degrees-of-freedom, parallel kinematics machine, with a high payload, to broad the range of materials to be tested, and allowing for a higher flexibility on tool-path generation. On the numerical side, preliminary results on simulation of SPIF processes resorting to an innovative solid-shell finite element are presented. The final target is an accurate and fast simulation of SPIF processes by means of numerical methods. Accuracy is obtained through the use of a finite element accounting for three-dimensional stress and strain fields. The developed formulation allows for an unlimited number of integration points through its thickness direction, which promotes accuracy without loss of CPU efficiency. Preliminary results and designs are shown and discussions over the obtained solutions are provided in order to further improve the research framework.