Numerical Modeling of Incremental Sheet Metal Forming Process for Generating Complex Shapes on Ti6Al4V

This article focuses on the simulation of complex-shaped parts made from a titanium alloy (Ti6Al4V) using incremental sheet metal forming (ISMF). The simulations were conducted through finite element (FE) analysis using the ABAQUS® software package. Linear brick S4R shell elements were utilized to discretize the sheet in the analysis to investigate the impact of different process parameters, including tool path, step height, and tool diameter, on the final shape and quality of the parts. In this study, triangular and circular lobe tool paths were simulated. For the triangular tool path, a tool diameter of 10 mm, step heights of 0.5 and 0.75 mm, height of 15 mm, and wall angle of approximately 34° were taken. For circular lobe-shaped tool path, tool diameters of 8 and 10 mm, step heights of 0.4, 0.5, and 0.8 mm, height of 20 mm, and wall angle of approximately 28° were taken. Simulations were conducted to study the influence of tool path, diameter, and step height on responses such as: forming force, reduction in sheet thickness, final depth, equivalent plastic strain, and the developed von Mises stress in the workpiece of thickness 1 mm.