Incremental Sheet Forming (ISF) is a progressive metal forming process, where the deformation occurs locally around the point of contact between a tool and the metal sheet. The final work-piece is formed cumulatively by the movements of the tool, which is usually attached to a CNC milling machine. The ISF process is dieless in nature and capable of producing different parts of geometries with a universal tool. The tooling cost of ISF can be as low as 5–10% compared to the conventional sheet metal forming processes. On the laboratory scale, the accuracy of the parts created by ISF is between ±1.5 mm and ±3mm. However, in order for ISF to be competitive with a stamping process, an accuracy of below ±1.0 mm and more realistically below ±0.2 mm would be needed. In this work, we first studied the ISF deformation process by a simplified phenomenal linear model and employed a predictive controller to obtain an optimised tool trajectory in the sense of minimising the geometrical deviations between the targeted shape and the shape made by the ISF process. The algorithm is implemented at a rig in Cambridge University and the experimental results demonstrate the ability of the model predictive controller (MPC) strategy. We can achieve the deviation errors around ±0.2 mm for a number of simple geometrical shapes with our controller. The limitations of the underlying linear model for a highly nonlinear problem lead us to study the ISF process by a physics based model. We use the elastoplastic constitutive relation to model the material law and the contact mechanics with Signorini’s type of boundary conditions to model the process, resulting in an infinite dimensional system described by a partial differential equation. We further developed the computational method to solve the proposed mathematical model by using an augmented Lagrangian method in function space and discretising by finite element method. The preliminary results demonstrate the possibility of using this model for optimal controller design.

O presente trabalho trata da análise numérica de cascas abatidas com o uso do método dos elementos de contorno (MEC). A formulação é desenvolvida a partir do acoplamento entre as equações integrais para flexão de placas delgadas e para estado plano de tensão. No esquema implementado, os termos sobre o contorno são avaliados a partir de processos analíticos e numéricos de integração. No caso das integrais de domínio, aplica-se um procedimento semi-analítico de cálculo sobre células discretas. A validação do modelo computacional desenvolvido é feita com base em resultados da literatura, obtidos com uso do método dos elementos finitos e dos elementos de contorno, além de soluções analíticas. / The present work deals with the numerical analysis of shallow shells using boundary element method (BEM). The formulation is developed by coupling integral equations of plate bending and plane stress elasticity. In the implemented scheme, the boundary terms are evaluated with analytical and numerical processes of integration. In the case of domain integrals, a semi-analytical calculation procedure is applied on discrete cells. The validation of developed computational model is made with results from other works, obtained by use of BEM or finite element method, besides analytical solutions.

The Finite Element Method (FEM) based computational mechanics is applied to simulate the optimal attenuation of vibrations in actively controlled structures. The simulation results provide the forces to be generated by actuators, as well as the structures response. Vibrations can be attenuated by applying either open loop or closed loop control strategies. In open loop control, the control forces for a given initial (or disturbed) configuration of the structure are determined in terms of time, and can be preprogrammed in advance. On the other hand, the control forces in closed loop control depend only on the current state of the system, which should be continuously monitored. Optimal attenuation is obtained by solving the optimality equations for the problem derived from the Pontryagins principle. These equations together with the initial and final boundary conditions constitute the two-point-boundary-value (TPBV) problem. <p>Here the optimal solutions are obtained by applying an analogy (referred to as the beam analogy) between the optimality equation and the equation for a certain problem of static beams in bending. The problem of analogous beams is solved by the standard FEM in the spatial domain, and then the results are converted into the solution of the optimal vibration control problem in the time domain. The concept of the independent-modal-space-control (IMSC) is adopted, in which the number of independent actuators control the same number of vibrations modes. <p>The steps of the analogy are programmed into an algorithm referred to as the Beam Analogy Algorithm (BAA). As an illustration of the approach, the BAA is used to simulate the open loop vibration control of a structure with several sets of actuators. Some details, such as an efficient meshing of the analogous beams and effective solving of the target condition are discussed. <p> Next, the BAA is modified to handle closed loop vibration control problems. The algorithm determines the optimal feedback gain matrix, which is then used to calculate the actuator forces required at any current state of the system. The methods accuracy is also analyzed.

The Finite Element Method (FEM) based computational mechanics is applied to simulate the optimal attenuation of vibrations in actively controlled structures. The simulation results provide the forces to be generated by actuators, as well as the structures response. Vibrations can be attenuated by applying either open loop or closed loop control strategies. In open loop control, the control forces for a given initial (or disturbed) configuration of the structure are determined in terms of time, and can be preprogrammed in advance. On the other hand, the control forces in closed loop control depend only on the current state of the system, which should be continuously monitored. Optimal attenuation is obtained by solving the optimality equations for the problem derived from the Pontryagins principle. These equations together with the initial and final boundary conditions constitute the two-point-boundary-value (TPBV) problem. <p>Here the optimal solutions are obtained by applying an analogy (referred to as the beam analogy) between the optimality equation and the equation for a certain problem of static beams in bending. The problem of analogous beams is solved by the standard FEM in the spatial domain, and then the results are converted into the solution of the optimal vibration control problem in the time domain. The concept of the independent-modal-space-control (IMSC) is adopted, in which the number of independent actuators control the same number of vibrations modes. <p>The steps of the analogy are programmed into an algorithm referred to as the Beam Analogy Algorithm (BAA). As an illustration of the approach, the BAA is used to simulate the open loop vibration control of a structure with several sets of actuators. Some details, such as an efficient meshing of the analogous beams and effective solving of the target condition are discussed. <p> Next, the BAA is modified to handle closed loop vibration control problems. The algorithm determines the optimal feedback gain matrix, which is then used to calculate the actuator forces required at any current state of the system. The methods accuracy is also analyzed.

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