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Single point incremental forming (SPIF) is a sheet forming process in which a CNC controlled tool is used to incrementally deform a blank into the desired shape. In heat assisted SPIF (HASPIF), an external heat source is used to elevate the temperature of the forming region to improve the formability of thermoplastic polymer sheets. The objective of this study is to compare HASPIF and room temperature SPIF of polycarbonate sheets using a coupled thermal-mechanical finite element model developed in ANSYS. The temperature dependent material behavior is simulated using the Three Network model, and the external moving heat load is applied using convective heat transfer coefficient (HTC) boundary conditions near the forming tool. The results indicate a reduction in forming forces (16.56%), reduction in springback (13.25%), and residual stresses (0.4 MPa) with HASPIF compared to room temperature SPIF.
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