An efficient and general finite element model for double-sided incremental forming

Newell Moser, David Pritchet, Huaqing Ren, Kornel F. Ehmann, Jian Cao*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

15 Scopus citations


Double-sided incremental forming (DSIF) is a subcategory of general incremental sheet forming (ISF), and uses tools above and below a sheet of metal to squeeze and bend the material into freeform geometries. Due to the relatively slow nature of the DSIF process and the necessity to capture through-thickness mechanics, typical finite element simulations require weeks or even months to finish. In this study, an explicit finite element simulation framework was developed in LS-DYNA using fully integrated shell elements in an effort to lower the typical simulation time while still capturing the mechanics of DSIF. The tool speed, mesh size, element type, and amount of mass scaling were each varied in order to achieve a fast simulation with minimal sacrifice regarding accuracy. Using 8 CPUs, the finalized DSIF model simulated a funnel toolpath in just one day. Experimental strains, forces, and overall geometry were used to verify the simulation. While the simulation forces tended to be high, the trends were still well captured by the simulation model. The thickness and in-plane strains were found to be in good agreement with the experiments.

Original languageEnglish (US)
Article number91007
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Issue number9
StatePublished - Sep 1 2016


  • DSIF
  • ISF
  • finite element
  • incremental forming

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering


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