Numerical Analyses of Long Fibers Reinforced Polymeric Sheets Processed by Single Point Incremental Forming

Abstract Polymeric matrix composites (PMCs) have gained increasing relevance in different industrial applications and their employment results to be a necessity in the production of lightweight structures. The manufacturing solutions, which allow to properly shape PMCs panels, need molds for shaping the material reducing the process flexibility. In this context, the single point incremental forming (SPIF) could be a valuable process solution if properly customized to the PMCs properties. Herein, a possible process variant is introduced and its capability in forming long fibers reinforced thermoplastics was evaluated. To achieve this aim, a numerical model was implemented focusing the attention, first, on the material properties that have to be considered for a proper model construction. The performed numerical simulations showed the applicability of SPIF to shape PMC sheets. Furthermore, the executed simulations pointed out the influences of some variables on the quality of the formed parts showing possible arising of defects, such as wrinkling and rippled surfaces, at different process conditions and providing a first proof of concept of the proposed working solution.