Finite Element Analyses of Conventional Single Point Incremental Forming and Friction Stir Incremental Forming of Aluminum Alloy Sheets

Friction stir incremental forming process for forming A5083 aluminum alloy sheets was calculated by finite element method. Conventional incremental forming process was also calculated and the both calculated results about distributions of temperature, plastic strain and deformation after springback were compared each other. Metallurgical change was not taken into account in the calculation. The maximum temperatures of sheet during forming in friction stir incremental forming and conventional incremental forming were 380 o C and 60 o C, respectively. Both distributions of equivalent strain in friction stir incremental forming and conventional incremental forming were almost uniform, however, absolute value in friction stir incremental forming was greater due to the shear strain introduced by tool rotation. Displacement in Z-direction by conventional incremental forming was uniform, however, that by friction stir incremental forming was not uniform since the temperature difference between during and after forming was large.Proceedings of the JSME/ASME 2014 International Conference on Materials and Processing ICMP2014 June 9-13, 2014, Detroit, Michigan, US