Numerical study on the thickness homogenization in hole-flanging by single-point incremental forming

Abstract

Incremental sheet forming is a novel technology that has significant benefits compared to conventional forming. However, it is a time-consuming process that is usually carried out in several forming stages to homogenize deformation and avoid material failure. In hole-flanging operations by SPIF, a single-stage strategy might provide functional flanges in considerably less time, however a non-uniform thickness is obtained along the flange. This work proposes a two-stage process as the best strategy to increase production rate, and an optimization methodology to produce a homogeneous thickness distribution of the flange. The procedure is used to automate the design process of parts and tool trajectories by CAD/CAM, and validate the optimal forming strategy by FEA.