Incremental Metal Forming of Functionally Graded Aluminum-Copper Composites: A Numerical Investigation by Finite Element Analysis

Manufacturers aim to produce high-quality, cost-effective products through advanced material forming techniques. This study utilized ABAQUS® software to present and evaluate a finite element model for the incremental forming process of a functionally graded aluminum-copper material (Al-Cu FGM). The developed model incorporated the Lagrangian dynamic framework and the Johnson-Cook constitutive equation. The model enabled accurate estimation of forces, stress, and strain distributions during the incremental forming process of an Al-Cu FGM. The results demonstrated that the algorithm effectively predicted these critical characteristics, which are significant for optimizing manufacturing processes. Although the model successfully replicated the material's stress responses, further refinement is necessary to enhance its accuracy. The study underscores the significance of understanding the behavior of material under different conditions, as well as the trade-offs between force application and material deformation, which can have a substantial impact on the manufacturing process. Continued refinement of such models will allow manufacturers to better predict material behaviors, ultimately leading to more resilient and efficient products.