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Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations

Single Point Incremental Forming (SPIF) is an innovative die-less low-cost forming method. Until now, there have not been viable numerical solutions regarding computational time and accuracy for the incremental forming of polymers. Unlike other numerical approaches, this novel work describes a coupl...

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Autores principales: García-Collado, A., Medina-Sanchez, Gustavo, Kumar Gupta, Munish, Dorado-Vicente, R.
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2020
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7465396/
https://www.ncbi.nlm.nih.gov/pubmed/32751705
http://dx.doi.org/10.3390/polym12081715
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author García-Collado, A.
Medina-Sanchez, Gustavo
Kumar Gupta, Munish
Dorado-Vicente, R.
author_facet García-Collado, A.
Medina-Sanchez, Gustavo
Kumar Gupta, Munish
Dorado-Vicente, R.
author_sort García-Collado, A.
collection PubMed
description Single Point Incremental Forming (SPIF) is an innovative die-less low-cost forming method. Until now, there have not been viable numerical solutions regarding computational time and accuracy for the incremental forming of polymers. Unlike other numerical approaches, this novel work describes a coupled thermomechanical finite element model that simulates the SPIF of polymer sheets, where a simple elastoplastic constitutive equation rules the mechanical behavior. The resulting simulation attains a commitment between time and accuracy in the prediction of forming forces, generated and transmitted heat, as well as final part dimensions. An experimental test with default process parameters was used to determine an adequate numerical configuration (element type, mesh resolution, and material model). Finally, compared to a set of experimental tests with different thermoplastics, the proposed model, which does not consider complex rheological material models, shows a good agreement with an approximation error of less than 11% in the vertical forming force prediction.
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spelling pubmed-74653962020-09-04 Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations García-Collado, A. Medina-Sanchez, Gustavo Kumar Gupta, Munish Dorado-Vicente, R. Polymers (Basel) Article Single Point Incremental Forming (SPIF) is an innovative die-less low-cost forming method. Until now, there have not been viable numerical solutions regarding computational time and accuracy for the incremental forming of polymers. Unlike other numerical approaches, this novel work describes a coupled thermomechanical finite element model that simulates the SPIF of polymer sheets, where a simple elastoplastic constitutive equation rules the mechanical behavior. The resulting simulation attains a commitment between time and accuracy in the prediction of forming forces, generated and transmitted heat, as well as final part dimensions. An experimental test with default process parameters was used to determine an adequate numerical configuration (element type, mesh resolution, and material model). Finally, compared to a set of experimental tests with different thermoplastics, the proposed model, which does not consider complex rheological material models, shows a good agreement with an approximation error of less than 11% in the vertical forming force prediction. MDPI 2020-07-30 /pmc/articles/PMC7465396/ /pubmed/32751705 http://dx.doi.org/10.3390/polym12081715 Text en © 2020 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
García-Collado, A.
Medina-Sanchez, Gustavo
Kumar Gupta, Munish
Dorado-Vicente, R.
Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations
title Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations
title_full Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations
title_fullStr Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations
title_full_unstemmed Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations
title_short Application of the Finite Element Method to the Incremental Forming of Polymer Sheets: The Thermomechanical Coupled Model and Experimental Validations
title_sort application of the finite element method to the incremental forming of polymer sheets: the thermomechanical coupled model and experimental validations
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7465396/
https://www.ncbi.nlm.nih.gov/pubmed/32751705
http://dx.doi.org/10.3390/polym12081715
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