Title: A finite element simulation of the incremental sheet forming process: a new method for G-code implementation

Authors: Mohamed Amen Gahbiche; Safa Boudhaouia; Eliane Giraud; Yessine Ayed; Philippe Dal Santo; Wacef Ben Salem

Addresses: Mechanical Engineering Laboratory, National Engineering School of Monastir, University of Monastir, Monastir, Tunisia ' Mechanical Engineering Laboratory, National Engineering School of Monastir, University of Monastir, Monastir, Tunisia ' LAMPA, Arts et Métiers ParisTech, 2 boulevard du Ronceray, 49035, Angers, France ' LAMPA, Arts et Métiers ParisTech, 2 boulevard du Ronceray, 49035, Angers, France ' LAMPA, Arts et Métiers ParisTech, 2 boulevard du Ronceray, 49035, Angers, France ' Mechanical Engineering Laboratory, National Engineering School of Monastir, University of Monastir, Monastir, Tunisia

Abstract: During the incremental sheet forming process, tool paths are generated by CAM software. The obtained files have several possible formats such as the APT or the G-code ones which can be directly transferred to CNC machines for parts forming. However, when it comes to the process simulation, the G-code format could not be used in common finite element programs. In this paper, a new method is developed to implement the G-code into the FE software Abaqus using the Python programming language. The G-code commands are translated into appropriate boundary conditions describing the exact forming tool motions without any decomposition or modification. The numerical results obtained by the proposed method and the conventional tool path decomposition method are compared in terms of the part shape, thickness distribution, forces evolution, and CPU times as well. On the other hand, a comparison of the surface roughness of two conical parts formed using these two formats has been conducted in order to investigate the potential effect of the tool path decomposition on surface quality.

Keywords: incremental forming; G-code; numerical simulation; CAM/CAE; tool path implementation; aluminium alloy; surface roughness.

DOI: 10.1504/IJMPT.2020.111314

International Journal of Materials and Product Technology, 2020 Vol.61 No.1, pp.68 - 86

Accepted: 07 Jul 2020
Published online: 19 Nov 2020 *

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