Finite element prediction of deformation mechanics in incremental forming processes

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http://eprints.org/relation/isVersionOf http://etheses.bham.ac.uk/id/document/62941 http://eprints.org/relation/isVolatileVersionOf http://etheses.bham.ac.uk/id/document/62941 http://eprints.org/relation/isIndexCodesVersionOf http://etheses.bham.ac.uk/id/document/62941 archive 4031 disk0/00/00/17/26 2011-07-04 08:43:52 2019-01-23 09:54:44 2011-07-19 16:40:49 thesis show 0 Essa Khamis Hartley Peter Cripps Robert University of Birmingham Finite element prediction of deformation mechanics in incremental forming processes unpub TJ 10col_ephy Thesis includes revisions accepted by the University in May 2018 16.8.18 - Following a complaint in relation to the original thesis revisions were approved by the University in May 2018. The uploaded version reflects those changes. Author also confirmed a change in access option to option A. The original thesis submission is stored here: O:\LIB\Dissertations_eTheses\Pre_2017_OnRepository\2011\Essa_1726_C This thesis presents new insights into gaps in the knowledge of conventional spinning and single point incremental forming (SPIF) processes through numerical modelling of their deformation mechanics. The deformation mechanics of conventional spinning is investigated by constructing finite element (FE) models of a cylindrical cup using both single and dual roller passes. A design of experiments (DOE) technique is used to generate an experimental plan based on all the relevant process parameters, followed by an analysis of variance (ANOVA) approach which is then used to determine the most critical parameters. The results indicated that the area in which most of the plastic deformation is taking place changes during the subsequent passes. The deformation mechanics of SPIF is investigated by constructing a novel dual-level finite element model of the forming of a truncated cone. The first-level FE model is validated against experimental data and the second level FE model is used to investigate the deformation modes through the sheet thickness. DOE and ANOVA techniques are used to investigate the influence of the different process parameters on the predicted through-thickness shear. Simple strategies are applied to reduce the geometrical errors without affecting the process flexibility. The results of the second-level FE model indicated that through-thickness shear is an important component in the deformation mechanism in SPIF. 2011-07 2011-06 graduation eng author This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder. public 255 University of Birmingham School of Engineering, Department of Mechanical Engineering d_ph na 2011-07 graduation