Modelling of Incremental Forming Processes

This paper on "Modelling of Incremental Forming Processes" was presented at the NAFEMS World Congress on The Evolution of Product Simulation From Established Methods to Virtual Testing & Prototyping - 24-28 April 2001, The Grand Hotel, Lake Como, Italy.

Introduction to Paper

The importance of metal forming in the field of industrial production is increasing continuously. By the use of forming technologies high efficiency and short production-times are feasible.
At the same time the share of incremental forming processes is rising. Today's market is characterised by a high diversification and complexity of demanded products. With the flexibility of incremental forming processes these requirements can be well achieved. Beyond that incremental forming processes can lead to high component integration. With the attempt to predict these processes with numerical computation methods new challenges are encountered. Difficulties and achievements will be discussed in the following.
Incremental forming processes are defined by the following characteristics:

• There are multiple steps to produce the targeted product
• It exists a sequential similarity of the steps
• There are intermittent boundary conditions
• Loading and unloading periodically take place at the same location of the work piece
• The tools are identical for more than one production step
• The deformation of the work piece occurs locally

Incremental forming processes are characterised by low tool forces and small tool costs. Due to the amount of high compressive stresses in the forming zone high strength materials can be processed. Important representatives of the process class mentioned are Flow-Forming, Ring Rolling, Spinning, Rotary Swaging and Axial-Radial-Forming.