A multiple-tool method for fast FEM simulation of incremental sheet forming process

Abstract In this paper, we proposed a multi-tool modeling method to reduce the finite element simulation computational time of incremental sheet forming (ISF) process. The aim is to study the computation efficiency and the prediction accuracy of thickness reduction and spring-back of ISF part using multi-tool simulation model. The tool paths necessary for this method were generated by an in-house code and can be extended for more complex geometries of ISF parts. The proposed multi-tool method allows for tremendous reductions in CPU time. To verify the proposed method, simulation models of ISF truncated cones shape were compared to the experimental results in terms of thickness distribution, forming forces and final part geometrical profile. The comparison results show that the developed multi-tool simulation approach can reduce the CPU time by up to 90% with satisfactory geometric accuracy as compared to traditional FE model. This study provides an important guideline for using FE simulation in design and manufacturing of large industry-sized ISF parts.