Abstract
The tool-sheet contact condition has significant effect on the crack occurring of forming parts in the single point incremental forming process. Experimental tests were carried out on sheets of 1060 aluminum and 2024 aluminum to form parts with varying wall angles under different contact conditions to explore the influence rule. Through the observation of the macro fracture depth and the microstructure of the micro fracture morphology, it is found that fracture depth of forming part is highest and the corresponding formability is best with hard alloy forming tool processed by the Cr/C coating with Molybdenum disulfide lithium base grease. The fracture occurring of the 1060 aluminum sheet is due to the instability of the sheet material, and the fracture of the 2024 aluminum sheet is due to its forming limit. In addition, it is also found that the fracture of single point incremental forming part occurs from the outer surface to the inner surface.
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