Finite Element Modeling and Validation of Effective Strain and Thickness Distribution on Incrementally Formed AA 3003 (O)

Incremental forming has gained attention in the field of sheet metal prototyping. The technique being flexible produces desired geometry in three-dimensional space without involving dedicated dies/punches utilizing spherical shaped tool. Higher order of deformation is achievable in this forming process. The versatility and adaptability of incremental forming make it applicable in various industries where complex shapes, lightweight structures, and customization are essential considerations. The current work presents a mathematical model for the prediction of effective strain generated due to deformation during incremental forming process. Annealed AA 3003 (O) of thickness 1 and 1.25 mm is utilized for the study. The strain component is evaluated in terms of geometrical variables of the formed section. Finite element model (FEM) for the strain behavior is established through ABAQUS explicit platform. Gridding procedure and video measuring technique is employed for evaluating experimental strain values. Thinning behavior of the formed components resulting from effective strain is also contemplated in the study. The results obtained from mathematical and FEM scheme corroborates fairly with the experimental findings.