Metal Forming Simulation Techniques
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Abstract
Abstract
Due to the lack of universal machines on the market, this paper presents a new technology and a dedicated machine for manufacturing sheet metal products with various geometries using a single set of tools.The study reports the results of numerical simulations of incremental forming of thin-walled products.The numerical analysis was performed on S355 steel sheets with thicknesses ranging from 1 to 5 mm.The bending line followed an arc-shaped trajectory.In the analyzed process, the sheet was deformed using two rollers: a shaping roller and a support roller.Simulations were carried out using Simufact Forming software.Process force parameters, as well as strain and stress distributions, were determined.The maximum forming forces obtained from the numerical simulations ranged from 2 kN for a sheet thickness of 1 mm to 24.5 kN for the maximum analyzed thickness of 5 mm.Preliminary numerical simulations indicate that wrinkling may occur in sheets with thicknesses of 1 mm and 2 mm, whereas for thicker sheets this instability was not observed in the simulations.The maximum effective plastic strain recorded for the 5 mm sheet was 1.15, while the maximum von Mises stress reached 724 MPa.Based on the simulation results, it can be stated that the proposed technology shows potential for industrial applications, particularly for single-unit production and prototyping.However, experimental validation is required.
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@article{Wjcik2026Capabilities,
title = {Capabilities of incremental forming of thin-walled products using a universal numerically controlled machine based on numerical simulations},
author = {Jarosław Wójcik and J. Tomczak and Tomasz Kusiak},
journal = {Advances in Science and Technology – Research Journal},
year = {2026},
doi = {10.12913/22998624/219862},
url = {https://doi.org/10.12913/22998624/219862}
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