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A new analytical model for force prediction in incremental sheet forming

Zhu, Hui; Ou, Hengan

A new analytical model for force prediction in incremental sheet forming Thumbnail


Hui Zhu

Associate Professor


A new analytical model for forming force prediction in the whole process of incremental sheet forming (ISF) is presented in this work. The modelling of contact region, thickness distribution and strain components are carried out as the basis for the prediction of vertical and horizontal forces. The effect of local contact behaviour and material deformation, as well as the behaviours of global bending, changes of deformation mode and contact condition are taken into account in the modelling of ISF force history. The force prediction model at both plane strain and biaxial tension condition areas is developed based on the differences in contact region and thickness distribution between these two different deformation states. Validated by ISF tests for a truncated cone and pyramid part with varying drawing angles, the prediction of force history captures well the fluctuation of different force components due to the change of deformation conditions and provides an insight into the material deformation mechanisms and the direct correlation to forming force characteristics of the whole ISF process. In a practical case, the model is successfully applied to the force prediction in ISF-based cranial plate manufacture. The model is also validated by a series of ISF tests with accurate force predictions of both the peak and stabilised forces.

Journal Article Type Article
Acceptance Date May 20, 2023
Online Publication Date May 22, 2023
Publication Date 2023-09
Deposit Date May 29, 2023
Publicly Available Date May 30, 2023
Journal Journal of Materials Processing Technology
Print ISSN 0924-0136
Publisher Elsevier BV
Peer Reviewed Peer Reviewed
Volume 318
Article Number 118037
Keywords Incremental sheet forming; Force prediction; Analytical method; Deformation behaviour; Contact condition
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