Optimization of relative tool position in accumulative double sided incremental forming using finite element analysis and model bias correction

Ebot Ndip-Agbor1, Jacob Smith1, Huaqing Ren1, Zhen Jiang1 , Jiachen Xu1 , Newell Moser1 , Wei Chen1 , Z. Cedric Xia2 , Jian Cao 1. International Journal of Material Forming, January 2015.

Show Affiliations
  1.  Northwestern University, 2145 Sheridan Road, Evanston, IL, USA
  2. Ford Motor Company, Dearborn, MI, USA. 


Double-Sided Incremental Forming (DSIF) uses two small, independently moving, hemispherical tools on either side of the sheet to form a desired shape by following a predefined tool path. This study was motivated by the observation that the relative tool position of the tools, specified in the tool path generation algorithm, affects the formed geometric accuracy. A methodology for defining the relative tool positioning in the tool path generation algorithm based on local part geometry is proposed using simplified Finite Element Analysis (FEA) and sample physical experiments combined with Gaussian Process modeling techniques. This approach can take into account the mechanics of deformation in DSIF explicitly and physical compliance of the DSIF machine implicitly. Physical experiments were performed to demonstrate the effectiveness of the proposed framework.

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