Critical factors, limits and applications in incremental forming

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Sheet metal forming has existed for many years as a manufacturing technique; forming refers to the deformation process through which a material is shaped by the addition of stresses causing the material to flow plastically. Incremental forming (IF) is a more modern process where small deformations are made in the material, a specific sequence of small deformations result in the desired shape. Single Point Incremental Forming (SPIF) is a highly flexible and cost effective new sheet metal forming process for limited quantity manufacturing. SPIF has the potential to have a significant impact on rapid prototyping, low quantity production and customized production. The process is extremely adaptable due to the lack of need for part specific forming dies and the use of equipment that is commonly found in machine shops. Forming is achieved by incrementally deforming material with the use of a generic fixture and forming tools.The advancements in SPIF have occurred as required. As the need arose for specific parts, a trial-and-error experimental studies were completed to determine how to produce the part. To make SPIF a practical manufacturing process in sheet metal forming, more fundamental research is needed to understand the process; thus eliminating the need for trial-and-error studies of individual parts. To advance the knowledge base of SPIF the undertaking of more methodical studies to determine effects the many process variables have on SPIF.The present research program will include fundamental experimetnal studies to determine critical factors; such as material type, material thickness, machine feedrate, tool size, lubrication type, etc. The proposed research builds on a previous parametric study, where only a small number of the variables were investigated. By undertaking this research greater knowledge of incremental forming is achieved, this will improve the opportunites for applications.