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Incremental forming (IF) is an advanced manufacturing process in which a forming tool locally deforms sheet material into a desired geometry through successive passes at incremental depths. An inherent benefit to the IF process is its formability improvement over conventional stamping; however, further enhancements will enable the forming of increasingly complex geometries. To progress the IF process towards heavy industrial use, the modeling of such processes must be further developed. Single point incremental forming (SPIF) of AA2024-T3 was modeled herein utilizing explicit formulations. The model geometry featured a nominally rectangular-shaped clamping region. A friction factor was experimentally determined and utilized within the model, which is a novel addition to this work. Formability was determined and forming limit diagrams were composed. It was found that the present model shows greater formability and underestimates plastic strain compared to experimental testing. The generation of forming limit diagrams for this material processed by IF is also a novel addition to this field. [ABSTRACT FROM AUTHOR]

Incremental forming (IF) is an advanced manufacturing process in which a forming tool locally deforms sheet material into a desired geometry through successive passes at incremental depths. An inherent benefit to the IF process is its formability improvement over conventional stamping; however, further enhancements will enable the forming of increasingly complex geometries. To progress the IF process towards heavy industrial use, the modeling of such processes must be further developed. Single point incremental forming (SPIF) of AA2024-T3 was modeled herein utilizing explicit formulations. The model geometry featured a nominally rectangular-shaped clamping region. A friction factor was experimentally determined and utilized within the model, which is a novel addition to this work. Formability was determined and forming limit diagrams were composed. It was found that the present model shows greater formability and underestimates plastic strain compared to experimental testing. The generation of forming limit diagrams for this material processed by IF is also a novel addition to this field.

Dispersion of the basal texture is effective to improve the formability. A repeated roll bending process (7 work rolls, work roll radius of 32 mm, roll pitch of 40 mm) was applied to AZ31 magnesium alloy sheets by activating the tensile twins. The larger applied bending strain per pass was effective to increase hardness at the surface of the sheet. The Erichsen value was slightly increased from 3.0 to 3.5 mm by subjected 2 passes repeated roll bending and subsequent at 180 °C for 12 hours annealing without decreasing the hardness of the sheet before bending (Hv=60). The Erichsen value of 3.3 and over hardness of Hv 65 through thickness were obtained by 2 passes bending and 160°C for 12 hours annealing. The tensile twins and texture randomizing were observed around center of thickness by electron backscatter diffraction (EBSD) analysis. It was possible to increase formability of AZ31 magnesium alloy by the repeated roll bending and subsequent low temperature annealing. [ABSTRACT FROM AUTHOR]