Experimental Investigation of Forming Forces in Single Point Incremental Forming

Single point incremental forming (SPIF) has been confirmed as a quiet economical process for rapid prototyping and batch-type production. It exempts complex and expensive tooling as required in the conventional sheet metal-forming processes. Investigation of forming forces becomes important for selecting the appropriate hardware and optimal process parameters in order to assure the perfection and precision of any process. Moreover, SPIF applicability can be ensured on the industrial scale when appropriate guidelines are highlighted regarding a relation between the input parameters and forming forces induced in the process. This paper investigates the influence of tool diameter, tool shape, and wall angle on the maximum axial forming forces on aluminum alloy (AA2024-O) sheets. Forming forces were recorded using a dynamometer and data logger system equipped with Microscada software. Tool shape has been proved a significant factor which affects the forming forces greatly. Combination of higher wall angle and flat-end tool with the lower side radius resulted in the fracture of components at a lower depth.