Abstract
Incremental sheet forming (ISF) is a flexible sheet metal forming process to realize products within short time from design to the first produced part. Although fundamental research on ISF has been carried out around the world, ISF still misses commonly required tolerances for industrial application. In this study, the influences of tool path as well as intrusion depth of the forming tool into the sheet material on the geometrical accuracy were investigated. In the conducted experiments, both flat and stretch-formed sheet metal blanks with different tool paths and intrusion depths were examined. Experimental and numerical investigations showed that changes in the range of a tenth millimeter of the intrusion depth with a consistent tool path lead to different resulting part geometries. A better understanding of the sensitive influence of the tool path and the intrusion depth on the resulting geometry might lead to more accurate parts in the future.
Highlights
Incremental Sheet Forming (ISF) has reached a high level of awareness in the industry as a forming technique for rapid prototyping or small batch production of sheet metal parts
This paper presents a simple test setup, To answer the questions on the influence of the tool path directions and the intrusion depths on the geometrical accuracy, experiments and finite element (FE) simulations were carried out using mild steel 1.0338
In the first setup for pure ISF, forming was focused on three different tool paths in combination with two different intrusion depths to investigate the influence of these parameters
Summary
Incremental Sheet Forming (ISF) has reached a high level of awareness in the industry as a forming technique for rapid prototyping or small batch production of sheet metal parts. The resulting geometrical accuracy depends on many influencing factors that are interdepending and, in many cases, cannot be controlled independently. This makes the process layout a complex and iterative process. Knowledge about these influencing factors is limited to the fact that it is known which influencing factor increases or decreases an effect, but not to what extent. One example for this is the tool diameter: the formability in ISF increases with decreasing tool diameter [1]. With the experience from many manufactured parts for various industries, the authors
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