| Abstract Scope |
Double-Sided Incremental Forming (DSIF) is a rapid-prototyping manufacturing process for metal forming that, for low-volume production, is competitively energy-efficient. However, controlling DSIF for arbitrary designs with respect to accuracy and formability is an ongoing challenge. These challenges arise due to a lack of understanding (and control) of the underlying deformation mechanisms in DSIF. And so, there is a need for high-fidelity simulations of DSIF that unravel these underlying complexities. Moreover, DSIF pushes the limits of today’s finite element formulations due to true strains that approach one, finite rotations, nonlinear contact, and triaxial stress states that range across multiple length scales. To confidently develop a finite element model of DSIF, an extensive verification and validation process must be considered, which is the objective of this study. Differing finite element types, boundary conditions, and amounts of artificial acceleration are compared, and recommendations based on efficiency and accuracy are summarized. |