Abstract
Nowadays, single point incremental forming (SPIF) process is gaining popularity for fabrication of various asymmetrical intricate sheet metal components in automobile, aerospace, ship-building, additive manufacturing and also in biomedical sectors. In the present work, a SPIF set up was designed and developed in-house to perform forming experiments using AA6061 thin sheet material. The fracture forming limit diagram (FFLD) was assessed experimentally using punch stretching test, and it was validated with the optimized SPIF test data. Further, an effort was made to modify the existing seven damage models implementing Hill48 anisotropy plasticity theory. Consequently, the effective plastic strains at the onset of fracture were predicted and compared with experimental data. All the critical damage parameters of investigated ductile fracture models were successfully calibrated using uniaxial tensile test data, and the theoretical FFLD was also estimated incorporating the anisotropy plasticity theory. Among the seven damage models, the Bao-Wierzbicki (BW) damage model was found to be the most efficient damage model with an average absolute error of 2.71%. Additionally, the influence of sheet metal anisotropy on the effective fracture strain was studied by comparing the fracture strain in 2D (η, LP) and 3D (\( \eta, {L}_P,{\overline{\varepsilon}}_f \)) fracture locus. In order to get insight into forming behaviour and surface roughness, the microstructural examination on the truncated dome fabricated using optimised parameters was carried out through micro texture analyses.
Similar content being viewed by others
References
Voswinckel H, Bambach M, Hirt G (2015) Improving geometrical accuracy for flanging by incremental sheet metal forming. Int J Mater Form 8(3):391–399. https://doi.org/10.1007/s12289-014-1182-y
Jeswiet J, Micari F, Hirt G, Bramley A, Duflou J, Allwood J (2005) Asymmetric single point incremental forming of sheet metal. CIRP Ann Manuf Technol 54(2):88–114
Duflou JR, Verbert J, Belkassem B, Gu J, Sol H, Henrard C, Habraken AM (2008) Process window enhancement for single point incremental forming through multi-step toolpaths. CIRP Ann Technol 57(1):253–256
Lu B, Ou H, Shi SQ, Long H, Chen J (2016) Titanium based cranial reconstruction using incremental sheet forming. Int J Mater Form 9(3):361–370. https://doi.org/10.1007/s12289-014-1205-8
Bahloul R, Arfa H, Belhadjsalah H (2014) A study on optimal design of process parameters in single point incremental forming of sheet metal by combining box-Behnken design of experiments, response surface methods and genetic algorithms. Int J Adv Manuf Technol 74(1-4):163–185. https://doi.org/10.1007/s00170-014-5975-4
Isik K, Silva MB, Tekkaya AE, Martins PAF (2014) Formability limits by fracture in sheet metal forming. J Mater Process Technol 214(8):1557–1565. https://doi.org/10.1016/j.jmatprotec.2014.02.026
Martins PAF, Bay N, Tekkaya AE, Atkins AG (2014) Characterization of fracture loci in metal forming. Int J Mech Sci 83:112–123. https://doi.org/10.1016/j.ijmecsci.2014.04.003
Habibi N, Zarei-hanzaki A, Abedi H (2015) Journal of materials processing technology an investigation into the fracture mechanisms of twinning-induced-plasticity steel sheets under various strain paths. J Mater Process Technol 224:102–116. https://doi.org/10.1016/j.jmatprotec.2015.04.014
Abedini A, Butcher C, Worswick MJ (2017) Fracture characterization of rolled sheet alloys in shear loading: studies of specimen geometry, anisotropy, and rate sensitivity. Exp Mech 57(1):75–88. https://doi.org/10.1007/s11340-016-0211-9
Bai Y, Wierzbicki T (2015) A comparative study of three groups of ductile fracture loci in the 3D space. Eng Fract Mech 135:147–167. https://doi.org/10.1016/j.engfracmech.2014.12.023
Park N, Huh H, Lim SJ, Lou Y, Kang YS, Seo MH (2017) Fracture-based forming limit criteria for anisotropic materials in sheet metal forming. Int J Plast 96:1–35. https://doi.org/10.1016/j.ijplas.2016.04.014
McAnulty T, Jeswiet J, Doolan M (2017) Formability in single point incremental forming: a comparative analysis of the state of the art. CIRP J Manuf Sci Technol 16:43–54. https://doi.org/10.1016/j.cirpj.2016.07.003
Fiorentino A, Marzi R, Ceretti E (2012) Preliminary results on Ti incremental sheet forming (ISF) of biomedical devices: biocompatibility, surface finishing and treatment. International Journal of Mechatronics and Manufacturing Systems 5(1):36–45. https://doi.org/10.1504/IJMMS.2012.046146
Feng JW, Zhan LH, Yang YG (2016) The establishment of surface roughness as failure criterion of Al–Li alloy stretch-forming process. Metals 6(1):13. https://doi.org/10.3390/met6010013
Hill R (1948) A theory of the yielding and plastic flow of anisotropic metals. Proc R Soc Lond A 193(1033):281–297. https://doi.org/10.1098/rspa.1948.0045
Basak S, Panda SK (2016) Application of Barlat Yld-96 Yield Criterion for Predicting Formability of Pre-Strained Dual Phase Steel Sheets. In: ASME 2016 11th International Manufacturing Science and Engineering Conference. p V001T02A063--V001T02A063
Basak S, Panda SK, Zhou YN (2015) Formability assessment of Prestrained automotive grade steel sheets using stress based and polar effective plastic strain-forming limit diagram. J Eng Mater Technol 137(4):041006. https://doi.org/10.1115/1.4030786
Bai Y, Wierzbicki T (2008) A new model of metal plasticity and fracture with pressure and lode dependence. Int J Plast 24(6):1071–1096. https://doi.org/10.1016/j.ijplas.2007.09.004
Bao Y, Wierzbicki T (2004) On fracture locus in the equivalent strain and stress triaxiality space. Int J Mech Sci 46(1):81–98. https://doi.org/10.1016/j.ijmecsci.2004.02.006
Lee YW (2005) Fracture prediction in metal sheets (PhD thesis). Massachusetts Institute Of Technology, Cambridge, United States
Considere A (1885) Use of the iron and steel in buildings. Ann Des Ponts Chaussees 9:574–575
Gorji M, Berisha B, Hora P, Barlat F (2015) Modeling of localization and fracture phenomena in strain and stress space for sheet metal forming. Int J Mater Form. https://doi.org/10.1007/s12289-015-1242-y
Silva MB, Nielsen PS, Bay N, Martins PAF (2011) Failure mechanisms in single-point incremental forming of metals. Int J Adv Manuf Technol 56(9-12):893–903. https://doi.org/10.1007/s00170-011-3254-1
Freudenthal AM (1950) The inelastic behavior of solids. Wiley, New York
Clift SE, Hartley P, Sturgess CEN, Rowe GW (1990) Fracture prediction in plastic deformation processes. Int J Mech Sci 32(1):1–17. https://doi.org/10.1016/0020-7403(90)90148-C
Cockcroft MG, Latham DJ (1968) Ductility and the workability of metals. J Inst Met 96:33–39
Tarigopula V, Hopperstad OS, Langseth M, Clausen AH, Hild F, Lademo OG, Eriksson M (2008) A study of large plastic deformations in dual phase steel using digital image correlation and FE analysis. Exp Mech 48(2):181–196. https://doi.org/10.1007/s11340-007-9066-4
Oh SI, Chen CC, Kobayashi S (1979) Ductile fracture in axisymmetric extrusion and drawing-part 2: workability in extrusion and drawing. Journal of Engineering for Industry 101(1):36–44. https://doi.org/10.1115/1.3439471
Brozzo P, Deluca B, Rendina R (1972) A new method for the prediction of formability in metal sheets, sheet material forming and formability. In: Proceedings of the Seventh Biennial Conference of the IDDRG
Rice JR, Tracey DM (1969) On the ductile enlargement of voids in triaxial stress fields∗. J Mech Phys Solids 17(3):201–217. https://doi.org/10.1016/0022-5096(69)90033-7
Nakazima K, Kikuma T, Hasuka K (1968) Study on the formability of steel sheets. Yawata Tech Rep 264:8517–8530
Basak S, Panda SK (2018) Implementation of Yld96 anisotropy plasticity theory for estimation of polar effective plastic strain based failure limit of pre-strained thin steels. Thin-Walled Struct 126:26–37
Dhara S, Basak S, Panda SK, Hazra S, Shollock B, Dashwood R (2016) Formability analysis of pre-strained AA5754-O sheet metal using Yld96 plasticity theory: role of amount and direction of uni-axial pre-strain. J Manuf Process 24:270–282. https://doi.org/10.1016/j.jmapro.2016.09.014
Prasad KS, Panda SK, Kar SK et al (2017) Microstructures, forming limit and failure analyses of Inconel 718 sheets for fabrication of aerospace components. J Mater Eng Perform 26(4):1513–1530
Panicker SS, Prasad KS, Basak S, Panda SK (2017) Constitutive behavior and deep Drawability of three aluminum alloys under different temperatures and deformation speeds. J Mater Eng Perform 26(8):3954–3969
Prasad KS, Gupta AK, Singh Y, Singh SK (2016) A modified mechanical threshold stress constitutive model for austenitic stainless steels. J Mater Eng Perform. https://doi.org/10.1007/s11665-016-2389-5
Gatea S, Ou H, McCartney G (2016) Review on the influence of process parameters in incremental sheet forming. Int J Adv Manuf Technol 87(1-4):479–499. https://doi.org/10.1007/s00170-016-8426-6
Emmens WC, Sebastiani G, van den Boogaard AH (2010) The technology of incremental sheet forming-a brief review of the history. J Mater Process Technol 210(8):981–997. https://doi.org/10.1016/j.jmatprotec.2010.02.014
Behera AK, de Sousa RA, Ingarao G, Oleksik V (2017) Single point incremental forming: an assessment of the progress and technology trends from 2005 to 2015. J Manuf Process 27:37–62
Silva MB, Skjoedt M, Atkins a G et al (2008) Single-point incremental forming and formability–failure diagrams. J Strain Anal Eng Des 43(1):15–35. https://doi.org/10.1243/03093247JSA340
Madeira T, Silva CMA, Silva MB, Martins PAF (2015) Failure in single point incremental forming. Int J Adv Manuf Technol 80(9-12):1471–1479. https://doi.org/10.1007/s00170-014-6381-7
Hagan E, Jeswiet J (2004) Analysis of surface roughness for parts formed by computer numerical controlled incremental forming. Proc Inst Mech Eng B J Eng Manuf 218(10):1307–1312
Hamilton K, Jeswiet J (2010) Single point incremental forming at high feed rates and rotational speeds: surface and structural consequences. CIRP Ann Manuf Technol 59(1):311–314. https://doi.org/10.1016/j.cirp.2010.03.016
Durante M, Formisano A, Langella A (2010) Comparison between analytical and experimental roughness values of components created by incremental forming. J Mater Process Technol 210(14):1934–1941
Bennett JM (1992) Recent developments in surface roughness characterization. Meas Sci Technol 3(12):1119
Prasad KS, Panda SK, Kar SK, Murty SVSN, Sharma SC (2018) Effect of solution treatment on deep drawability of IN718 sheets: experimental analysis and metallurgical characterization. Mater Sci Eng A 727:97–112. https://doi.org/10.1016/j.msea.2018.04.110
Masoumi M, Santos LPM, Bastos IN, Tavares SSM, da Silva MJG, de Abreu HFG (2016) Texture and grain boundary study in high strength Fe-18Ni-co steel related to hydrogen embrittlement. Mater Des 91:90–97. https://doi.org/10.1016/j.matdes.2015.11.093
Goel S, Jayaganthan R, Singh IV, Srivastava D, Dey GK, Saibaba N (2015) Texture evolution and ultrafine grain formation in cross-cryo-rolled zircaloy-2. Acta Metallurgica Sinica (English Letters) 28(7):837–846. https://doi.org/10.1007/s40195-015-0267-z
Weibel ER (1989) Measuring through the microscope: development and evolution of stereological methods. J Microsc 155(3):393–403
Osakada K, Oyane M (1971) On the roughening of free surface in deformation processes. Bulletin of JSME 14(68):171–177
Dai K, Villegas J, Shaw L (2005) An analytical model of the surface roughness of an aluminum alloy treated with a surface nanocrystallization and hardening process. Scr Mater 52(4):259–263. https://doi.org/10.1016/j.scriptamat.2004.10.021
Savoie J, Zhou Y, Jonas JJ, Macewen SR (1996) Textures induced by tension and deep drawing in aluminum sheets. Acta Mater 44(2):587–605. https://doi.org/10.1016/1359-6454(95)00214-6
Rossiter J, Brahme A, Inal K, Mishra R (2013) Numerical analyses of surface roughness during bending of FCC single crystals and polycrystals. Int J Plast 46:82–93. https://doi.org/10.1016/j.ijplas.2013.01.016
Acknowledgements
Authors are thankful to Mr. A. Mehto, Mr. J. Bagchi and Mr. Y. Shiva Ganesh of Department of Mechanical Engineering, IIT Kharagpur for their help while conducting single point incremental forming experiments.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare that they have no conflict of interest.
Additional information
Publisher’s Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Basak, S., Prasad, K.S., Sidpara, A.M. et al. Single point incremental forming of AA6061 thin sheet: calibration of ductile fracture models incorporating anisotropy and post forming analyses. Int J Mater Form 12, 623–642 (2019). https://doi.org/10.1007/s12289-018-1439-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12289-018-1439-y