Finite Element Simulation and Analysis of TPIF Process for Irregular and Complex-Shaped Components

The two-point incremental forming (TPIF) technique is recognized as an advanced approach for fabricating shell-type components. Unlike the single-point incremental forming (SPIF) method, the incorporation of a counter tool or bottom die introduces additional complexities in the forming process. As a result, finite element analysis (FEA) becomes crucial for minimizing experimental iterations, anticipating material failure such as sheet tearing, and analyzing different parameters influencing this sophisticated process. While prior research has primarily focused on the simulation of SPIF, these studies typically employed geometrically simple shapes—such as truncated cones, hemispheres, and pyramids—defined by standard mathematical models. In contrast, the present study proposes a streamlined strategy for simulating TPIF of free-form surfaces. The methodology integrates computer-aided manufacturing (CAM)-based extraction of tool path coordinates with finite element modeling. This study demonstrates how simulation outcomes can offer valuable insights into failure mechanisms, aid in selecting appropriate numerical tools for real-world applications, and evaluate the quality of sheet deformation.

کلیدواژه ها:

Two-Point Incremental Sheet Forming (TPIF) ، Finite Element Analysis (FEA) ، Numerical Modeling ، Complex Freeform Geometries