International Journal of Recent Technology and Engineering (IJRTE)

ISSN: 2277-3878, Volume-8, Issue-4, November 2019

Numerical Simulation of Single Point

Incremental Forming for Deep Drawing Steel
Zeradam Yeshiwas, A. Krishniah

 Drawing quality steel (DDQ) is one of the commonly used

Abstract: The present study was designed to determine the steel in the automotive industry. Single Point Incremental
effect of tool diameter, feed rate and step depth on the thickness forming processes presented in this work was achieved with a
distribution and forming force using finite element simulation in deep drawing quality (CR3) cold-rolled steel sheet with a
single point incremental forming (SPIF). Deep drawing steel is
the material used for the study. The findings clearly indicate that; sheet thickness of 1 mm. The chemical composition and
with decrease the step depth, feed rata and tool diameter more Mechanical properties of DDQ steel are described in Table I
stretching of the sheet can achieved and that means thinning rate and II respectively.
can be reduced. When the tool diameter, feed rate and step depth The uniaxial tensile test was conducted to obtain the true
increase the forming force also increase. These findings have stress-strain curve and subsequently, the mechanical
significant implications for the understanding of how process properties of DDQ steel with a sheet thickness of 1 mm. The
parameters affect forming force and thinning in SPIF of Deep
Drawing Steel (DDQ).
dimensions of the specimen are obtained according to ASTM
E8M standard. The obtained values then introduced to define
Keywords: DDQ, Forming force, Incremental forming, SPIF, material properties-plasticity for simulation of SPIF process.
Thickness distribution

I. INTRODUCTION

S ingle point incremental sheet forming is an emerging

process for manufacturing sheet metal parts and it is well
suited for small batch production or prototyping. In SPIF
sheet is formed into the desired final part by a series of small
incremental deformations until the part fully formed (Fig. 1.).
In the past decade, numerous researches related to
Incremental Sheet Forming has been focused on Fig. 1. Single point incremental sheet forming and basic
experimental investigations of the process. Based on the elements
quantitative literature review made by [1], the experimental
approach has used in most of the studies. While simulation is Table- I: Chemical composition of DDQ steel
an emerging practice in the study of the single point Designation Name Composition
incremental sheet forming process. CR3 Deep Drawing
C% Mn% S% P%
Numerical simulation studies on the process are growing 0.1 0.45 0.03 0.025
from time to time. However, most of the investigations have .
been focused on aluminum alloys [2]-[6]. Furthermore, steel Table- II: Mechanical properties of DDQ steel
Name Composition
materials such as Extra deep drawing steel (EDD) and Yield Stress 220 MPa
stainless steel have investigated [7]-[9]. Tensile Strength 350MPa
There is a relative paucity of studies specifically relating to Density 7.85e-6 kg/mm3
the numerical simulation of SPIF using deep drawing steel Modulus of Elasticity 210,000N/mm3
(DDQ). The main goal of this explicit numerical simulation Poisson’s ration 0.3
study on deep drawing steel is to evaluate the effect of
process parameters on thickness distribution and forming
force. The parameters chosen includes tool diameter, step II. METHOD
depth and feed rate. The flow chart (Fig.2.) depicted the process that was used for
the numerical simulation of SPIF.
Three geometries have chosen namely Truncated Cone,
Revised Manuscript Received on …., 2019. Truncated Pyramid, and Hyperbola to verify the thickness
* Correspondence Author
distribution (thinning) and force magnitude in the numerical
Zeradam Yeshiwas*, Department of Mechanical Engineering,
University college of Engineering, Osmania University, Hyderabad, India. simulation. The 3D model of the truncated cone and
Country. Email: zeruhulu@gmail.com hyperbola have largest opening of 100mm diameter and the
Arkanti Krishnaiah, Department of Mechanical Engineering, University pyramid has 100mm of largest
college of Engineering, Osmania University, Hyderabad, India. Country. width and length. All the
Email: arakanti@gmail.com
sample parts have a depth of
30mm.
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 Numerical Simulation of Single Point Incremental Forming for Deep Drawing Steel

3D Model (CAD) III. NUMERICAL SIMULATION

The numerical simulation is carried on a computer machine
Toolpath Definition (CAM) equipped with an Intel® Core™ i7–3632QM Quad-Core
processor (2.20 GHz) and the Windows 7 Professional
G-Code Generation (64-bit platform) operating system.
In this study, ABAQUS is the software used for the finite
Extracting Coordinate Points element simulation combined with the characteristics of
SPIF.
Numerical Simulation ABAQUS implicit requires long computational time.
Fig.2. Flow chart for the numerical simulation of SPIF. Because of this, the ABAQUS explicit method has chosen for
the conduct of the Numerical Simulation.
Contour toolpath was defined by using Mastercam For finite element simulations, the blank is modeled as a
environment. The parameters used for the definition of square of 200 mm X 200 mm X 1 mm in size and is fixed at
toolpath are described in Table III. Fig. 3 shows the toolpath its four edges (Fig. 4). Blank is defined as a deformable body
defined for the chosen parts. and meshed with shell elements (S4R). It is a 4-node,
The G-code created was extracted to coordinate points by quadrilateral, stress/displacement shell element with reduced
using the Excel approach to define the displacement integration and a large-strain formulation. Initial element size
(amplitude versus time) data for the numerical simulation is taken as 2 mm. The friction coefficient of 0.15 has used
[10]. between the tool and the forming sheet.
Table -III: Parameters for the toolpath definition
Parameters
Feed Rate Tool Wall
Part Step Depth
(mm/min) Diameter Angle
(mm)
(mm)
0.5 500 8 45º
Truncated Pyramid
1 500 8 45º
1 1000 12 50º
Truncated Cone
1 1000 8 50º
0.8 800 10 30-78º
Hyperbola
0.8 1000 10 30-78º

(a)

Fig. 4. Single point incremental forming model.

Hemispherical forming tools of 8 mm, 10mm and 12mm

diameter have chosen and defined as analytical rigid part.
Table-II depicts the blank material properties, the elastic
behavior specified in numerical simulations. To define the
displacement, the position vs time data was introduced to
ABAQUS software.
(b) The computation time required for simulation of SPIF
process by implicit method is double the time taken for
simulation by using explicit method even for small parts.
However, prediction of accurate geometry remains a problem
in the simulations done by the explicit method. The explicit
methods however, become unstable and diverge rapidly over
large time increments [11].
In this study mass scaling has used to minimize the
computational time. Mass scaling is done by increasing the
(c) density of material.
In explicit method, bounded
Fig. 3. Toolpath definition for the (a) Truncated Cone, (b)
Truncated Pyramid (c) Hyperbola solution is obtained only when the
time increment (∆t) is less than the

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 International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8, Issue-4, November 2019

stable time increment (∆tmin). If ∆t ≥ Δtmin, the solution will be From this observation more thickness reduction (thinning)
unstable and oscillations will occur in the model’s response can achieved by using larger tool diameter. Similar results
[12]. The stability limit is the ratio between Characteristic has also been made by [3], [5].
length of the element and the Wave speed.
t  Le / Cd (5)
In mass scaling, the kinetic energy should be monitored to
ensure that the ratio of kinetic energy to internal energy does
not get too large typically less than 10% [12].
The criterion that time increment (∆t) is less than the stable
time increment (∆tmin) and kinetic energy must be small
relative to internal energy has been satisfied in all three
numerical simulations. Fig. 5 shows the Kinetic energy to (a)
internal energy ratio in forming the Truncated Cone,
Truncated Pyramid and Hyperbola.
1800000 IE VERSUS KE

1600000
IE Pyramid 0.5mm step
1400000 KE Pyramid 0.5mm step
IE Pyramid 1mm step
1200000 b)
KE Pyramid 1mm step
Fig. 6. Effect of step depth on thickness distribution at step
IE Hyperbola 800mm/min
depth of a) 0.5mm and b) 1mm.
1000000 KE Hyperbola 800mm/min
ENERGY

IE Cone 8mm
800000
KE Cone 8mm
IE Cone 12mm
600000
KE Cone 12mm
IE Hyperbola 1000mm/min
400000
Fig.5. Internal energy combined with kinetic energy history KE Hyperbola 1000mm/min

IV. RESULA AND DESCATION

(a)
This section has attempted to provide a brief summary of the
numerical simulation result relating to the effect of tool
diameter, feed rate and step depth on thickness distribution
and the forming force.
A. Thickness Distribution
If to and tf are initial and final thickness of the part with wall
angle α with horizontal then the final thickness can be
predicted by using the sin law [13]. After the stable thinning
an interrupted excessive thinning can occur and the result can
deviate from the sin law.
b)
t f  to  sin(90   ) (5)
Effect of Step Depth on Thinning: As shown in Fig. 6, Fig. 7. Effect of tool diameter on thickness distribution a)
0.55mm (45%) thinning is achieved for the truncated 8mm diameter and b) 12mm mm diameter.
pyramid with 1mm step depth and 0.65mm (35%) thinning is
achieved with 0.5mm step depth. Effect of Feed Rate on Thinning: Fig. 8 displays the results
From this observation more thickness reduction (thinning) obtained from the effect of feed rate on thickness
can achieved by using larger steep depth. Similar results has distribution. Based on the result, 0.41(58.5%) thinning is
also been made by [3], [7]. achieved using 1000mm/min feed rate and 0.43 (56.9%)
Effect of Tool Diameter on Thinning: As displayed in Fig. thinning is achieved using 800mm/min feed rate.
7, 0.68mm (32%) thinning is achieved for the truncated cone Based on the simulation result, more thinning can achieved
with 12mm diameter tool and 0.69mm (31%) thinning is by using higher feed rate.
achieved with 8mm diameter tool. Similar results has also been
made by [5], [8].

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 Numerical Simulation of Single Point Incremental Forming for Deep Drawing Steel

(a)

Fig. 9. Effect of tool diameter depth on forming force

Truncated Pyramid
4000

3000

Force(N)
2000

b) 1000
Fig. 8. Effect of feed rate on thickness distribution (a)
800mm/min feed rate and (b) 1000mm/min feed rate. 0
0 400 800 1200 1600
Time(s)
B. Forming force
Fig.9, 10 and 11 shows the evaluation of punch force Fig. 10. Effect of step depth on forming force
magnitude in forming different sample parts. The force
versus time graph is plotted.
Hyperbola
The truncated cone, was chosen to evaluate the effect of 4000
tool diameter on the forming force. The truncated pyramid
was chosen to evaluate the effect of step depth on the forming 3000
force and the Hyperbola was used to evaluate the effect of
2000
Force(N)

feed rate on the forming force.

Effect of Tool Diameter on Forming Force: as shown in 1000
Fig. 9, the maximum force magnitude is 2647.95N for the
0
Truncated Cone with 12mm diameter tool and 2309.57N for
0 100 200 300 400 500
8mm diameter tool. Time(s)
Effect of Step Depth on Forming Force: As shown in Fig
Feed 800mm/min Feed 1000mm/min
10, the maximum force magnitude is 3845.91N for the
Truncated Pyramid with 1mm step depth and 3051.51with
0.5mm step depth. Fig. 11. Effect of feed rate on Force in forming force
Effect of Feed Rate on Forming Force: as shown in Fig.
11, the maximum force magnitude is 3497.52N for the 4000
Hyperbola with 1000mm/min feed rate and 2677.88N for
3000
800mm/min diameter tool.
From the result all the maximum forces registered with the
Force(N)

2000
maximum tool diameter, feed rate and step depth.
The combined plot of all the three factors is shown in Fig. 1000
12. The graph shows that step depth has more effect on the 0
forming force than tool diameter and feed rate. Feed rate has 0 200 400 600 800 1000
more effect on the forming force than tool diameter. Time(s)
Step 1mm
Tool Diameter 12mm
Feed 1000mm/min

Fig. 12. Comparison of effect of

process parameters on the forming
force

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 International Journal of Recent Technology and Engineering (IJRTE)
ISSN: 2277-3878, Volume-8, Issue-4, November 2019

CONCLUSION 12. Abaqus analysis User’s manual, explicit dynamic analysis.

13. J. Jeswiet, D. Young, “Forming limit diagrams for single-point
incremental forming of aluminium sheet,” Journal of Engineering
The following conclusions can be drawn from the present Manufacture, vol.219,no 4, pp. 359–364, 2005.
study.
 The maximum thinning variation is observed on the AUTHORS PROFILE
Truncated Pyramid i.e. 10% thinning variation between
the part formed by using 0.5mm and 1mm step depth. First Author profile which contains their education
This proves that the step depth has a major effect on Author-1 details, their publications, research work, membership,
Photo achievements, with photo that will be maximum 200-400
thinning.
words.
 Tool diameter has a relatively minor effect on thinning.
i.e. 1% thinning variation between the part formed by
using 8mm and 12mm diameter tools. This shows that
tool diameter has more effect on thinning than feed rate Author-2 Second Author profile which contains their education
but less effect than step depth. Photo details, their publications, research work, membership,
 From the observations made on the results of the achievements, with photo that will be maximum 200-400
words.
numerical simulation, the maximum thinning is
observed on the Hyperbola i.e 59% and 57% thinning
achieved. This shows that the forming angle also has an
effect on the thickness distribution. When the wall angle
increase from 30º to 78º the thinning also increases.
 The force in forming deep drawing steel in SPIF is
increased with the increase in the tool diameter, step
depth and feed rate by considering the other parameters
constant.
The present study lays the groundwork for future research
into the effect of process parameters in single point
incremental forming of Deep Drawing Steel. Considerably
more work will need to be done to determine the optimum
combination of process parameters.

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