Integrating CAM and numerical simulation to investigate single point incremental forming of Al6061 | ||
| Journal of Engineering Science and Military Technologies | ||
| Article 1, Volume 4, Issue 1, March 2020, Pages 109-120 PDF (1.99 M) | ||
| Document Type: Original Article | ||
| DOI: 10.21608/ejmtc.2020.27784.1141 | ||
| Authors | ||
| Amr Shaaban1; Ahmed Samy Elakkad* 2 | ||
| 1Department of Designs and Production, Faculty of Engineering, Ain Shams University, Cairo, Egypt | ||
| 2design and production engineering, Ain shams university, Cairo, Egypt | ||
| Abstract | ||
| Single point incremental forming, SPIF, is a forming process that has a great potential application in sheet metal industries. SPIF is capable of producing medium size batches of complex shapes with low cost as it requires no die. This study explores the potentials of integrating computer aided manufacturing, CAM, and finite element analysis, FEA, to obtain a virtual model that realistically simulates the SPIF process. The simulation of SPIF process has been carried out using LS-Dyna4.3© software while producing a circular and rectangular taper pockets on a blank made of AL6061. The tool path has been generated using a CAM software and imported to a CNC machine to execute the SPIF process, taking into consideration the main forming parameters: the feed rate and the incremental step size. The results of both simulation and experiment are presented against each other in terms of thickness reduction, spring back, and cross-sectional profile, and they are proved to be close within an accepted range. The virtual model obtained in this the study is believed to be useful for performing an optimization analysis to decide the optimum forming parameters that are thought to affect the SPIF process. | ||
| Keywords | ||
| CAM; CNC; metal forming simulation; SPIF | ||
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