VALIDATION OF FINITE ELEMENT MODEL FOR STRAIN ANALYSIS OF SINGLE POINT INCREMENTAL FORMING PROCESS

Abstract

Motivated by the need to improve strain distribution prediction in single point incremental forming process, this study investigates the results obtained from a numerical model developed, in   comparison with experimental results. The problem addressed is the limited experimental validation of finite element predictions, which reduces confidence in process simulations. Using ABAQUS, a detailed model with the help of finite element method was developed and applied to truncated cone parts formed by a KUKA industrial robot. Strain and thickness data were obtained from experimental investigations using a 3D optical measurement system and compared to numerical predictions. The results showed slight overestimations of the numerical model, particularly in minor strains, but overall deviations remained within acceptable limits. The model reliably predicts strain distributions, confirming its applicability for predicting strain distribution in single point incremental forming process and improving manufacturing outcomes.