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<p>Incremental forming (IF) is a rapid prototyping technology that can achieve lower costs and shorter cycles for complex sheet metal forming compared to traditional forming techniques. However, obtaining a uniform thickness distribution across the entire formed part is a challenge due to the local deformation characteristics of sheet metal during IF. A finite element (FE) iterative control method based on a deformation machining was proposed to address this issue. This method utilizes an FE iterative process to generate the 3D digital model of tailored sheets that can achieve thickness uniformity by local thickness compensation. Then, the tailored sheets are produced through a milling process based on the 3D digital model. Finally, the sheet metal parts with improved thickness uniformity are fabricated from the tailored sheets using IF. Verification experiments performed on variable curvature truncated cones and profiled parts demonstrate the effectiveness of the proposed method for enhancing sheet metal thickness distribution. The proposed technique can improve thickness distribution uniformity by approximately 60–75% compared to traditional even-thickness sheet forming. Additionally, the improvement efficacy of this method can be further enhanced by improving the accuracy of the FE.</p>

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Research on thickness uniformity based on FE iterative control

  • 期刊论文

  • 发表日期：

    2025年6月25日

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  • Luteng Liu,
  • Shihong Lu,
  • Long Li,
  • Saisai Liu,
  • Yujie Shi

摘要

Incremental forming (IF) is a rapid prototyping technology that can achieve lower costs and shorter cycles for complex sheet metal forming compared to traditional forming techniques. However, obtaining a uniform thickness distribution across the entire formed part is a challenge due to the local deformation characteristics of sheet metal during IF. A finite element (FE) iterative control method based on a deformation machining was proposed to address this issue. This method utilizes an FE iterative process to generate the 3D digital model of tailored sheets that can achieve thickness uniformity by local thickness compensation. Then, the tailored sheets are produced through a milling process based on the 3D digital model. Finally, the sheet metal parts with improved thickness uniformity are fabricated from the tailored sheets using IF. Verification experiments performed on variable curvature truncated cones and profiled parts demonstrate the effectiveness of the proposed method for enhancing sheet metal thickness distribution. The proposed technique can improve thickness distribution uniformity by approximately 60–75% compared to traditional even-thickness sheet forming. Additionally, the improvement efficacy of this method can be further enhanced by improving the accuracy of the FE.