About the Enhanced Formability of

Single Point Incremental Forming

AM Habraken, CF Guzmn

SPIF Description
Single Point Incremental Forming process

SPIF Description

[Jeswiet et al. 2005]

Vasilakos et al., 2011

Formed Parts

Funnel

Solar cooker

Headlight

reflector

[Duflou et al. 2008]

Cranial Plate

SPIF applications
Honda S800 hood

[Emmens et al., 2010]

Airbus A320 hydraulic

door
[Hirt et al., 2015]

SPIF deformation mechanisms

Plane strain ?

-Through Thickness Shear

-Hydrostatic component
Wall angle
g
(neg.) ng
n

Hirt et al. ICTP conf (2002)

Tool
rotation

NO

nt

YES

Frict
coeff

13

23

2 nt

2 ng

0.00
0.05
0.09
0.35
0.09

-7
-7
-7
-5
-4

6
9
11
22
7

n
t

Eycken et al. Int J Mat Forming 4 (1) 2011

Henrard et al. Comp Mech 47 (5) 2010

SPIF deformation mechanisms

Serrated strain path
Major principal strain
( in radial direction)

Cone 50 Outer element

0,4

0,3

0,2

0,1

0
-0,01

0,01

0,02

Minor principal strain

( in circumferential direction)

Bending
Compression within sheet
thickness

FLC Forming Limit Curves

-Radial strain path
-Plane strain (no normal stress, no shear stress)

Assumptions

1) Necking event
2) Crak event

SPIF does not respect these hypotheses

Formability approach
Effect of TTS (Through Thickness Shear)

Extended version of
MarciniakKuczynski
method
By Eyckens
FLC curve increases
[Eyckens et al., 2009]

Formability approach
Effect of compression stress in thickness direction
coupled with plane stress
Nurcheshmeh
& Green
ESAFORM
(2011)

SPIF formability reported in FLC

SPIF formability closer
to failure prediction
and not necking one

[Reddy et al., 2015]

Jeswiet et al. 2005

Emmens et al. 2009

Effect of tool radius

(effect of thickness and material)
If triaxiality T SPIF formability ( Necking then fracture)
If triaxiality T SPIF formability (Fracture without necking)

Damage approach: phenomenological model

Malhotra et al. [2012]:
Cone test simulated by Xue [2007] damage model.
Phenomenological mode, based on I1-J2-J3
J3 Lode angle + Pressure term

Funnel

Cone

[Malhotra et al., 2012]

Noodle Theory (Malhotra 2012 )

diffuse necking in SPIF
begins earlier compare to
punch forming, but
localized necking occurs
later.
In SPIF, a material point
undergoes diffused
necking but the tool
moves and deforms new
material.
The previously formed
region is able to take up
some of the deformation
caused in next paths.

Too simple scheme forget 3D strain

Damage approach: Gurson model

DC01 steel

SIN law t f t0 sin( )

2
1.0 t f 0.35 mm

Let us try an extended

Gurson model

GTN model
(Guzmans PhD thesis 1-02-2016 ULg)
Yield criterion [Gurson, 1977]:
2

3 m
eq
*
*
* 2
Fp , f , Y 2 1 2q1 f cosh q2
q1 f 0
Y
2 Y
Von _ Mises

Damage

Void evolution:
Nucleation [Chu and Needleman, 1980]
Growth
Coalescence [Tvergaard and Needleman, 1984]
Shear [Nahshon and Hutchinson, 2008]
+Voce or Swift isotropic hardening +Armstrong Frederick Kinematic hardening
+ Hill Anisotropic yield locus
+ careful identification: tensile test, notch tensile test, shear test, line test for DC01 steel

SPIF Cone Simulations

Material: DC01 steel (1.0mm thickness)
Experimental failure angle: 67.
Simulation using the LAGAMINE FE code, RESS solid-shell
element [Alves de Sousa, 2006], GTN + shear damage model.

SPIF Cone simulation

Aerens et al. [2009]
formula: F_z=1222 [N]
Force overestimated
(quite classical, see
benchmark NUMISHEET
2014 + Sena et. al 2015)
Predicted limit angle: 47
Experimental one: 67

Discussion
GTN + shear: failure location OK but failure moment OK

Why?

No strong coupling between damage evolution and hardening

Localized necking not accurately predicted
Link with a localization criterion ? Thomason ?
not convinced too early prediction, not too late
Modify the coalescence model // Xue [2007]
damage model based on I1-J2-J3
further from physic ?? shear extension
Coalescence model not adapted to SPIF where gradient effect through
the thickness happens
Needleman nucleation law : not correctly linked with hydrostatic stress
(see Balan et. al 2015)
What about mesh sensitivity

References

R. Aerens, P. Eyckens, A. van Bael, and J. Duflou, Force prediction for single point incremental
forming deduced from experimental and FEM observations, Int. J. Adv. Manuf. Technol., vol. 46,
no. 912, pp. 969982, 2009.

T. Balan, X. Lemoine, E. Maire, A. Habraken, (2015, September) Implementation of a

damage evolution law for dualphase steels in Gurson-type models. Materials and Design,
(88), 1213-1222.

C. C. Chu and A. Needleman, Void Nucleation Effects in Biaxially Stretched Sheets, J. Eng. Mater.
Technol., vol. 102, no. 3, p. 249, 1980.
J. Duflou, J. Verbert, B. Belkassem, J. Gu, H. Sol, C. Henrard, and A. M. Habraken, Process window
enhancement for single point incremental forming through multi-step toolpaths, CIRP Ann. Manuf. Technol., vol. 57, no. 1, pp. 253256, 2008.
W. C. Emmens, G. Sebastiani, and A. H. van den Boogaard, The technology of Incremental Sheet
Forming-A brief review of the history, J. Mater. Process. Technol., vol. 210, no. 8, pp. 981997, Jun.
2010.
P. Eyckens, A. van Bael, and P. van Houtte, Marciniak-Kuczynski type modelling of the effect of
Through-Thickness Shear on the forming limits of sheet metal, Int. J. Plast., vol. 25, no. 12, pp.
22492268, 2009.
A. L. Gurson, Continuum theory of ductile rupture by void nucleation and growth: Part I-Yield
criteria and flow rules for porous ductile media, J. Eng. Mater. Technol., vol. 99, no. 1, pp. 215,
1977.
Jeswiet, J., Duflou, J., Szekeres, A., Levebre, P. Custom Manufacture of a Solar Cooker a case
study in Journal Advanced Materials Research, Vols. 6- 8, May 2005, pp 487-492.

References

J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, and J. Allwood, Asymmetric Single Point
Incremental Forming of Sheet Metal, CIRP Ann. - Manuf. Technol., vol. 54, no. 2, pp. 88114, Jan.
2005.

W. C. Emmens and a. H. van den Boogaard, An overview of stabilizing deformation mechanisms in

incremental sheet forming, J. Mater. Process. Technol., vol. 209, no. 8, pp. 36883695, Apr. 2009.

CF. Guzman PhD thesis 1/2/2016 (soon uploaded on institutional library ORBI ULg)

G. Hirt, M. Bambach, W. Bleck, U. Prahl, and J. Stollenwerk, The Development of Incremental

Sheet Forming from Flexible Forming to Fully Integrated Production of Sheet Metal Parts, in
Advances in Production Technology, C. Brecher, Ed. Cham: Springer International Publishing, 2015,
pp. 117129.

R. Malhotra, L. Xue, T. Belytschko, and J. Cao, Mechanics of fracture in single point incremental
forming, J. Mater. Process. Technol., vol. 212, no. 7, pp. 15731590, 2012.

K. Nahshon and J. W. Hutchinson, Modification of the Gurson Model for shear failure, Eur. J.
Mech. - A/Solids, vol. 27, no. 1, pp. 117, 2008.

N. V. Reddy, R. Lingam, and J. Cao, Incremental Metal Forming Processes in Manufacturing, in

Handbook of Manufacturing Engineering and Technology, A. Y. C. Nee, Ed. London: Springer London,
2015, pp. 411452.

V. Tvergaard and A. Needleman, Analysis of the cup-cone fracture in a round tensile bar, Acta
Metall., vol. 32, no. 1, pp. 157169, 1984.

I. Vasilakos, J. Gu, H. Vanhove, H. Sol, and J. Duflou, Deviations between FE Simulation and
Experiments in the SPIF Process, in Key Engineering Materials, 2011, vol. 473, pp. 937946.

L. Xue, Damage accumulation and fracture initiation in uncracked ductile solids subject to triaxial
loading, Int. J. Solids Struct., vol. 44, no. 16, pp. 51635181, 2007.