Papers abstract:

Incremental sheet forming is a promising process for sheet metal prototyping and for bio-medical implants. The entire process cycle is computer integrated and part is manufactured on a computer numerical control (CNC) milling machine. This process uses a spherical-ended tool to press the sheet into the required shape. The path of the tool is controlled by a part program generated using computer-aided manufacturing (CAM) software. For the numerical simulation of the process, the tool has to follow the same path as in experimental work. But numerical simulation software normally does not accept the G-code file generated using CAM packages directly. In the present paper, a methodology has been proposed to input the tool path trajectories generated using CAM packages into numerical simulation software such as ABAQUS and LS-DYNA. For certain sample symmetric and asymmetric shapes, this proposed methodology has been implemented in MATLAB and LS-DYNA. The results were found to be satisfactory.

Product Overview:
This Abaqus-based tutorial recreates the single point incremental forming (SPIF) simulation described in the ISI paper. It demonstrates how to convert G-code into simulation-ready tool paths and accurately reproduce complex forming geometries. Key simulation steps include:

• Implementing tool motion using Abaqus Amplitude and Displacement/Rotation BCs
• Simulating sheet deformation using explicit dynamics in Abaqus
• Modeling asymmetric and curved geometries with realistic forming behavior

In this tutorial, incremental forming of complex geometries is simulated, according to data from the work of Kurra Suresh et al.