Forming Parameters and Forming Defects in Incremental Forming of an Aluminum Sheet: Correlation, Empirical Modeling, and Optimization: Part A

Abstract

Single point incremental forming (SPIF) has potential to be employed commercially and can replace conventional sheet stamping process if its defects, such as poor geometrical accuracy, can be overcome. In the present article, three forming defects, namely, squeezed out wall formation, corner fold corner, and bulge height, are introduced. It is demonstrated that the formation of these defects has adverse effect on the formability in SPIF. In order to eliminate, if possible, the formation of these defects, the potential effect of operating (i.e., tool radius and step size), geometrical (i.e., wall angle), and material (i.e., sheet thickness and material property) parameters and their interaction on the defect formation and growth has been quantitatively investigated by employing response surface design method. With the help of proposed empirical models, the investigated defects can be overcome through parametric optimization.