Modelling of Incremental Bulk and Sheet Metal Forming

In incremental forming operations, forming is accomplished by a number of single, local forming steps with simple, generic tools, and in some cases even by laser or plasma beams. This makes incremental forming processes very flexible. However, complex tool kinematics with a large number of degrees of freedom can cause severe problems for process planning and optimization. In addition, new questions regarding the material behaviour under cyclic plastic deformation arise. This article gives an overview of current problems in the finite element modelling of incremental forming processes, focusing on two examples, hammer forging and incremental CNC sheet metal forming. Based on this, insight is given into current research at the Metal Forming Institute (IBF) regarding adapted simulation methods for incremental forming processes.