Predication of Forming Limit Diagram and Spring-back during SPIF process of AA1050 and DC04 Sheet Metals

Incremental sheet forming process (ISF) has been demonstrated its large potential to manufacture and fabricate three-dimensional complex shapes which are needed in different industrial sectors. In this paper, an attempt has been made in term of formability to identify the maximum forming angle of AA1050 aluminium alloy and DC04 carbon steel through manufacturing a frustum cone by using single point incremental forming process (SPIF). Investigation of forming angle is considered as an important index for choosing the optimal and suitable forming process parameters to avoid the demerits of crack initiation and fracture risks. In order to make a satisfying investigation, a numerical simulation is developed at the same of the experimental parameters, therefore, ANSYS V.18 (workbench LS-DYNA) was applied to create A 3D- finite element model of frustum cone product with different forming angle and the analysis of the results has been done with aid of LS-PREPOST software to evaluate the influence of forming angle on the forming limit diagram (FLD), residual stresses, and spring-back. The Cowper Symonds power law hardening was adopted to simulate the elastic-plastic behavior and assuming the isotropic properties were used to model the plasticity behavior of AA1050 aluminum alloy and DC04 carbon steel during the SPIF process. The results exhibit that the DC04 carbon steel has the highest formability where the maximum forming angle reaches 75° whereas it was 72° for AA1050 aluminum alloy.