Colloquia

Summary

Double-Sided Incremental Sheet Forming (DSIF) is a promising sheet metal forming technique that
can be used to produce complex geometries without the need for part specific tooling. Currently,
its adoption is limited due to low geometric accuracy, largely caused by insufficient localization
of the forming conditions and elastic springback. In this work, it is aimed to exploit the full
flexibility of the support tool by prescribing a support tool force along a loading axis that is
defined relative to the forming tool position. The displacement Degrees of Freedom (DOF) which
define the position of the support tool relative to the forming tool, as well as the loading orientation
and magnitude of the prescribed support force can all be adapted during forming, leading to an
extremely large process design space. A systematic numerical study is performed to investigate the
effects of different support tool parameters on the forming accuracy. This is done by constructing
a surrogate model that is fitted to a large set of Finite Element Method (FEM) simulations. Using
this model, a substantial part of the forming parameter space is explored and relations between
the desired geometry and optimal forming conditions are sought, with the objective to maximize
geometric accuracy.