Efficient implicit simulation for incremental forming

Single Point Incremental Forming (SPIF) is a displacement controlled process performed on a CNC machine. A clamped blank is deformed by the movement of a small sized tool that follows a prescribed tool path. An extensive overview of the process has been given in [1]. The tool size plays a crucial role in the SPIF process. The small radius of the forming tool concentrates the strain at the zone of deformation in the sheet under the forming tool. The tool has to travel a lengthy forming path all over the blank to introduce the deformation. Numerically, this requires performing thousands of load increments on a relatively fine FE model resulting in enormous computing time. A typical computing time for implicit simulation of a small academic test is measured in by days. The focus of this paper is to efficiently use the implicit time integration method in order to reduce the required computing time for incremental forming implicit simulation drastically.