Numerical simulation of incremental sheet forming
with considering yield surface distortion
Z. M. Yue
X. R. Chu
J . Gao
Received: 10 October 2016 /Accepted: 7 March 2017 /Published online: 20 March 2017
Springer-Verlag London 2017
Abstract The incremental sheet forming processes (ISF) are
attracting lots of attentions due to their advantages on rapid
prototyping, without special dies and short lead time. The
numerical simulation can be a valid method to investigate
the forming process and predict the defects. In this study, an
extended fully coupled ductile damage model with mixed
nonlinear hardening was used to simulate the ISF process.
At the same time, the yield surface distortion was also consid-
ered in this model, which can enhance the capability of model-
ing metallic material behavior under complex loading paths.
Afterwards, some simulations were conducted with the pro-
posed model. Additionally, one tension-shear orthogonal
loading test was assigned on the one representative element
in order to investigate the loading path effect during ISF pro-
cess. By comparing the equivalent plastic strain and ductile
damage evolution of the blank, the influence of the yield sur-
face distortion on the ISF process was proved.
Keywords Incremental sheet forming
Incremental sheet forming (ISF) is well known as an in-
novative process for sheet metal forming. With the help of
ISF, a suitable forming process for custom required small
batch production quantities can be finished [1, 2]. By
computer numerical control (CNC), the forming tool can
move as prescribed tool path flexibly, without special dies
suited for mass production. Cost in realizing such process
is rather low. Traditionally, the blank edge should be held
in binder and can be moved freely in the vertical direc-
tion, and an employed support can improve the processing
accuracy (Fig. 1).
However, some typical defects appear during the forming
process, like thinning and cracks [3–5]. In order to predict
these defects, lots of researches have been conducted [6, 7].
Different methodologies like forming limit diagrams (FLD,
FLSD), fracture criterions, have been used for the failure
prediction of ISF process. Bael et al. have ever used
Marciniak-Kuczynski (MK) model to predict necking onset
of ISF process with considering the non-monotonic loading
paths. Maria et al. have tried to determine the formability
limits of aluminum alloy sheet by necking (FLD) and frac-
ture (FFL) and tested them in a single point ISF process .
Martins et al. have built one theoretical model based on
membrane analysis and ductile damage mechanics .
This model can well explain the major parameters influence
during single point ISF process. They also proved that single
point ISF formability is limited by fracture without necking.
The similar conclusion also has been got by Isik et al. .
With the development of finite element analysis, the duc-
tile damage model has attracted more attentions, which can
help researchers simulate and investigate the loading path
Electronic supplementary material The online version of this article
(doi:10.1007/s00170-017-0269-2) contains supplementary material,
which is available to authorized users.
* X. R. Chu
School of Mechanical, Electrical and Information Engineering,
Shandong University, Weihai, China
Int J Adv Manuf Technol (2017) 92:1761–1768