This document discusses formability effects of process parameters on forming forces in single point incremental forming. It provides an abstract that the study aims to optimize forming parameters like step depth, tool feed and spindle speed using single point incremental forming. The document then reviews conventional sheet metal forming processes and incremental sheet metal forming. It discusses types of incremental forming and applications of single point incremental forming before listing references.

1. Formability Effects of Process Parameters
on Forming Forces in Single Point
Incremental Forming Process

2. CONTENTS
 Abstract
 Introduction
 Literature review
 Inference from literature review
 Research Gap
 Objective of the study
 Reference
10/16/2023
2

3. ABSTRACT
 This study is to optimize the forming parameters such as forming
step depth, tool feed and spindle speed using Single Point
Incremental Forming.
 Surface roughness and wall thickness have been considered as
the responses from the inputs and taken into account..
 Forming angle, sheet metal thickness, tool diameter, spindle
speed, step depth and tool feed are the parameters that control the
material flow during incremental forming process. Controlling
these parameters during forming leads to better formability.
 Comparison of Forming Limit Diagram (FLD) and wall
thickness on the formed components.
 Experiments were validated performing numerical simulation
and the material behaviour has been analyzed.
10/16/2023
3

4. INTRODUCTION
CONVENTIONAL SHEET METAL FORMING
 Sheet metal forming processes are those in which force is
applied to a piece of sheet metal to modify its geometry rather
than remove any material.
 The applied force stresses the metal beyond its yield strength,
causing the material to plastically deform, but not to fail. By
doing so, the sheet can be bent or stretched into a variety of
complex shapes.
 Sheet metal forming processes include the Bending, Roll
forming, Spinning, Deep Drawing, Stretch forming.
 Ductile materials are preferable, the most commonly used
being aluminum, steel, and titanium.
10/16/2023
4

5. CONVENTIONAL SHEET
METAL FORMING PROCESS
10/16/2023
5
Figure.1 Bending of sheet metal with a die
Figure.2 Edge bending of sheet metal

6. 10/16/
2023
6
Figure 3 Roll forming process (www.rollerdie.com)
CONVENTIONAL SHEET
METAL FORMING PROCESS

7. 10/16/2023
7
CONVENTIONAL SHEET
METAL FORMING PROCESS
Figure.4 Stretch forming process
Figure.5 Spinning process of sheet metal using roller

8. INCREMENTAL SHEET
METAL FORMING
 Incremental sheet forming (or ISF, also known as Single Point Forming)
is a sheet metal forming technique where a sheet is formed into the final
work piece by a series of small incremental deformations.
 Generally, the sheet is formed by a round tipped tool, typically 5 to 20mm
in diameter.
 The tool, which can be attached to a CNC machine, a robot arm or similar,
indents into the sheet by about 1 mm and follows a contour for the desired
part.
 It then indents further and draws the next contour for the part into the
sheet and continues to do this until the full part is formed.
 ISF can be divided into variants depending on the number of contact
points between tool, sheet and die (in case there is any).
 The term Single Point Incremental Forming (SPIF) is used when the
opposite side of the sheet is supported by a faceplate and Two Point
Incremental Forming (TPIF) when a full or partial die supports the sheet.
10/16/2023
8

9. INCREMENTAL SHEET
METAL FORMING
10/16/2023
9
Figure.4 Classification of incremental sheet forming

10. TYPES OF INCREMENTAL
FORMING
10/16/2023
10
Figure.5 Two point incremental
Forming process
Figure.6 Single point incremental
forming process

11. APPLICATIONS OF SPIF
 SPIF was initially developed for the necessity of shipping,
construction, automobile and aerospace industries.
 Complex shapes such as the human face and cranial implants have
been manufactured using this process.
 The applications of AA2024/AA 3003/AA4043/AA 5182/AA6061
alloy are boiler making, name plates, containers, road signs, welded
tubes, pressure vessels and etc.,
 This material can be used for light weight, low maintenance,
decorative finish, corrosion resistant applications.
 ‘Ford Company’ uses it as Free Form Fabrication Technology (F3T)
in rapid prototyping of automotive parts.
 ‘Sirris’ uses it as Kinematic Incremental Sheet Metal Forming that
uses two pins.
10/16/2023
11

12. REFERENCES
 Goodwin, GM 1968, ‘Application of strain analysis to sheet metal forming in the
press shop’, SAE Paper No.680093.
 Ham, M &Jeswiet, J 2006, ‘Single point incremental forming and the forming criteria
for AA3003’, Annals of CIRP, vol. 55, pp. 17-21.
 Ham, M &Jeswiet, J 2007,‘Forming limit curves in single point incremental forming’,
CIRP Annals – Manufacturing Technology, vol. 56, pp. 277-280.
 Hanliang Zhu, Gosh, AK &Maruyama, K 2006, ‘Effect of cold rolling on
microstructure and material properties of 5052 alloy sheet produced by continuous
casting’, Materials science and engineering A, vol. 419, pp. 115-121.
 Harvey, DN 1984, ‘Optimizing patterns and computational algorithms for automated,
optical strain measurement in sheet metal in efficiency in sheet metal forming’,
Proceedings of the 13th Biennial Congress, Melbourne, Australia, IDDRG, pp. 403-
414.
 He, S, Van Bael, A, Van Houtte, P, Szekeres, A, Duflou, JR, Henard C & Habraken,
AM 2005, ‘Finite Element Modeling of Incremental Forming of Aluminum Sheets’,
Advanced Materials Research, vol. 6, no. 8, pp. 525-532.
 Henrard,C, Habraken, AM, Szekeres, A, Duflou, JR, He, S, Van Bael, A & Van
Houtte, P 2005, ‘Comparison of FEM Simulations for the Incremental Forming
Process’, Advanced Materials Research, vol.6-8, pp. 533-542.
10/16/2023
12