Improving the accuracy of double-sided incremental forming simulations by considering kinematic hardening and machine compliance

Double-Sided Incremental Forming (DSIF) is a subcategory of Incremental Sheet Forming (ISF) that utilizes two tools to provide squeezing support to achieve improved formability and dimensional accuracy. Due to the complexity and geometric nonlinearities associated with DSIF, the finite element (FE) method is a suitable analysis tool to further analyze the process mechanics and predict forming forces. However, little research that is specific to DSIF has been conducted in relation to identifying the critical factors that affect the accuracy of the simulation in terms of the forming forces. In this study, material kinematic hardening as well as machine compliance are explored as simulation factors to improve the accuracy of force predictions in DSIF simulations. The results suggest that machine compliance – a factor often assumed to be negligible in existing research – plays a pivotal role in achieving the correct trends in the simulated forces.