Impact of Step Size, Spindle Speed and Sheet Thickness on Forming Force in SPIF

Abstract

Single Point Incremental Forming (SPIF) is a viable and flexible forming technique that has great potential to fulfil the need of various emerging areas like automobile and aerospace sectors. In addition, this technique has the ability to trigger the revolution in rapid prototyping and batch-type production of sheet material components. The flexibility and the ability to be economical can save the energy that in turn makes this process ready for green manufacturing. The prediction and measurement of forming forces during the SPIF process determine the size of forming machinery and additional hardware along with preventing the failures of facilities. This work focuses on the investigation of some significant input factors of this die-less process on maximum axial forming forces. The detailed knowledge about the impact of input factors would help the researchers and engineers to increase the viability of this process on an industrial scale. Results showed that components can be formed by minimal axial forces (886 N) when a combination of lower sheet thickness (0.8 mm, in this case) and lower step size (0.2 mm, in this case) are taken into account. Thicker sheets can be formed with smaller forming forces by employing higher spindle speed, and energy can be saved up to a larger extent.