Abstract
The incremental sheet forming (ISF), also known as die-less forming, has the potential to form complex three-dimensional objects. It has a higher formability limit than the conventional forming. ISF is the method of producing complex sheet metal components with enhanced productivity and improved quality. Further, the ISF can also be applied in various levels of manufacturing. Major advancements in the ISF have proved the manufacturing flexibility of the process. The present research work discusses important findings on various factors like wall angle, tool material, step depth, spindle speed, and feed corresponding to the response which is related to wall thickness, roughness, geometry, and forming angle. Such features are found to be the characteristic formability feature in the ISF. The entire process has been investigated by using numerical analysis software. The final fabrication includes designing the fixtures for clamping sheet metals, and suitable programming inputs have been given to the CNC machine. In addition to the analytical results, various iterations in the ISF of IS513Cr3 have been conducted by changing the wall angle correspondingly. The computational results of the ISF are compared with the actual values obtained from the experimentation, and various process parameters have been investigated and studied.
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