Birmingham Environment for Academic Research - University of ...

Evaluation of deformation mechanisms in single point incremental forming SPIF (SingleMany of the previous investigations have focused on an analysis of deformation mechanics of SPIFthrough experimental investigations or by using the finite element (FE) method. The work, however,is contradictory with different views on the detailed deformation modes. From a review of the literature,it was suggested that stretching and thinning are the dominant modes of deformation. Conversely,experimental measurements from some investigations indicated that high values of transverseshear are present through the thickness. Numerical methods, for example FE modelling, permita detailed study of complex deformation behaviour and as experimental observations of through-thickness phenomena are extremely difficult, modelling of the SPIF processes becomes an essential tool.The aim is to evaluate the presence of through-thickness shear deformation through a multi-level FE approach and to investigate howit is affected by the process parameters. Additionally, improve the geometrical accuracy without affecting the process flexibility.Using a dual-level FE modelling approach, a significant value of through-thickness shear in two planes is predicted. One of theseplanes is perpendicular to the tool movement and the other is parallel to the tool direction. This suggests that this shear strain couldbe a major contribution to the increase in the forming limit of the material in this process. Simple strategies such as adding a backingplate, using a kinematic supporting tool and tool path optimization result in considerable improvement in the geometrical accuracy ofthe final product.Khamis EssaSchool of Mechanical EngineeringPage 22