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Study on thickness reduction rate of single point incremental forming parts

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Document pages: 11 pages

Abstract: The excessive thickness reduction rate in the deformation zone of sheet metal single point incremental forming has an important influence on the forming limit. The thickness prediction of deformation zone is an important way to control the thinning rate. Taking 1060 Aluminum Alloy as the research object, the principle of thickness deformation in single point incremental forming is analyzed; The finite element model is established by ABAQUS software. According to the simulation results, a high-precision prediction formula of deformation zone thickness is fitted, and the effects of process parameters such as tool diameter, step, feed rate, sheet thickness and forming angle on thinning rate are analyzed. The accuracy of finite element simulation is analyzedverified by experiment. A method to control the thinning rate by changing the forming trajectory was proposed. The results showed that the obtained value by using the fitted formula is closer to the experimental results than that obtained by the sine theorem. The thinning rate of the deformation zone increases with the increase of tool diameter, forming angle, and sheet thickness and decreases with the increase of step down, while the feeding speed had no significant effect on the thinning ratio. The most important factor of the thinning ratio is the forming angle, and the thinning ratio can be effectively reduced by using the forming trajectory with a uniformly distributed pressing point.

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