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Single Point Incremental Forming (SPIF) is a new and dieless forming process. Since the process is in its initial phase, it requires rigorous analysis to form the sheet metal in the most efficient way. Usually, experimental execution of SPIF for both small component with complex features and large components with simpler geometry demands time and is cost ineffective. Thus, numerical simulation of the process is practiced beforehand to extensively analyze the process characteristics and to evaluate the complex state of stress and strain evolved in the process. In the case of a dynamic process, like SPIF, it is a general practice to minimize computational time and for the purpose, reduced integrated shell elements are used. However, during simulation, it was observed that an increase in strain caused geometrical distortion of the simulated part due to wrinkling which was originated because of hourglass phenomenon. The present work utilizes a fully integrated four node element to eliminate the hourglass effect in SPIF. The geometrical accuracy, plastic strain and von Mises stress developed during SPIF, with reduced and fully integrated shell elements were further evaluated and compared.

Efficiency Enhancement of Single Point Incremental Forming Simulation by Mitigating Hourglass Phenomenon