Simulation of incremental sheet metal forming for making U-channel in two light-weight alloys

Abstract

Incremental sheet metal forming (ISMF) is a viable method for fabricating complicated three-dimensional structures from sheet metal. It is characterized by localized deformation and is effective for both rapid prototyping and low-volume manufacturing. ISMF technology is suitable for quick product development time with affordable tooling and for deforming difficult-to-form materials. Simulation of the process reduces costly hit-and-trial attempts for manufacturing an accurate product. This article presents the simulation for producing a U-channel made of aluminum (Al 6061-T6) and titanium (Ti-6Al-4V) alloys. A finite element method (FEM) package, ABAQUS®, has been used for simulation using shell elements. The effect of various parameters on the forming forces is discussed using two different tools, flat and hemispherical-end.