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<p>Single point incremental forming (SPIF) has been studied extensively&#xa0;for the past few decades and remains unique due to the higher forming limits often achieved in this process. The role of through-thickness shear (TTS) strain components on the formability is still not unambiguously established for SPIF. In this study, SPIF of drawing quality steel sheets was performed using two different tool diameters. The subsequent microstructure characterization revealed strengthening of the gamma fiber, viz., &lt;111&gt;|| ND. However, when the intensity of this fiber was very high at a 15&#xa0;mm tool diameter, the 10&#xa0;mm tool diameter resulted in a relatively lower intensity. 3D finite element (FE) simulations of the process revealed that the magnitude of TTS components was high at a 10&#xa0;mm tool diameter. Crystal plasticity fast Fourier transform simulations using the input velocity gradient derived from FE simulations revealed that the deviation of grains from &lt;111&gt;|| ND at a 10&#xa0;mm tool diameter occurred because of the higher magnitude of TTS components. Moreover, the higher TTS components resulted in a more heterogeneous distribution of effective stresses and strains and caused strain localizations. These strain localizations were correlated with the Taylor factor of the grains present in the vicinity. Finally, the presence of high TTS was observed to render the grains in a state where the Taylor factor was low, indicating the possibility of more plastic deformation and hence provide higher limits of forming, provided the stress/strain concentrations do not become critical to initiate fracture.</p>

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The role of through-thickness shear in single point incremental forming: a micromechanical perspective

  • 期刊论文

  • 发表日期：

    2025年8月8日

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  • K. U. Yazar,
  • Vivek Kumar Barnwal,
  • Ashish Kumar Saxena,
  • Anand Krishna Kanjarla,
  • Prashant P Date,
  • K Narasimhan

摘要

Single point incremental forming (SPIF) has been studied extensively for the past few decades and remains unique due to the higher forming limits often achieved in this process. The role of through-thickness shear (TTS) strain components on the formability is still not unambiguously established for SPIF. In this study, SPIF of drawing quality steel sheets was performed using two different tool diameters. The subsequent microstructure characterization revealed strengthening of the gamma fiber, viz., <111>|| ND. However, when the intensity of this fiber was very high at a 15 mm tool diameter, the 10 mm tool diameter resulted in a relatively lower intensity. 3D finite element (FE) simulations of the process revealed that the magnitude of TTS components was high at a 10 mm tool diameter. Crystal plasticity fast Fourier transform simulations using the input velocity gradient derived from FE simulations revealed that the deviation of grains from <111>|| ND at a 10 mm tool diameter occurred because of the higher magnitude of TTS components. Moreover, the higher TTS components resulted in a more heterogeneous distribution of effective stresses and strains and caused strain localizations. These strain localizations were correlated with the Taylor factor of the grains present in the vicinity. Finally, the presence of high TTS was observed to render the grains in a state where the Taylor factor was low, indicating the possibility of more plastic deformation and hence provide higher limits of forming, provided the stress/strain concentrations do not become critical to initiate fracture.