Predictive modeling of incremental bulk metal forming processes

Project aim

To develop a methodology of robust modelling, including numerical process modelling and physical downscaled modelling, of flow forming and rotary forming processes suitable for industrial implementation.

Project background

Incremental bulk metal forming processes allow the manufacture of large components from materials with limited ductility. While offering a high level of flexibility, the process has a narrow manufacturing window due to the required set process parameters, which often results in errors during production, resulting in high operational costs and low efficiency. The use of process modelling offers a challenging yet effective alternative, and this project will explore different methodologies that can be adopted for robust modelling of incremental bulk processes for industrial applications.