Numerical Study of a Variable Wall Angle Made of DC01 Steel by Incremental Forming Process

Nowadays, there is a high demand for rapid prototyping parts and for products manufactured through plastic cold deformation. Incremental forming process is one of many which presents numerous advantages for fast production of complex shape parts. The purpose of this study is to develop a numerical model through finite element analysis to simulate the incremental forming process. For this analysis a variable wall angle part (VWA) which ranges from a 45° wall angle at the higher base of frustrum cone to a 70° wall angle at the base of the shape was proposed. The numerical model showed where the maximum strains are localized, how big the forces are during the process and how much the material thinned. Although the model does not indicate a possible failure of the material, the integrity of the structural stiffness was altered due to a minimum thickness reached of just 0.26mm.