Reduction of geometric deviation by multi-pass incremental forming combined with tool path compensation for non-axisymmetric aluminum alloy component with stepped feature

Abstract

Incremental sheet forming (ISF) is a new and rapid forming process which produces parts without using specific die. One of the key challenges is geometric accuracy especially for complex sheet metal parts. In the presented work, a typical non-axisymmetric part of AA5052 with stepped feature was studied through orthogonal experiments with 4 parameters in 4 levels to determine the optimal process parameters for better geometric accuracy. Based on the optimum process parameters, the strategy on further reducing geometric deviation was investigated, and the compensation was made on each tool path during multi-pass incremental forming. The intermediate configurations were designed to avoid the interaction of different features and improve the smoothness of material flow. Based on the proposed methodology, the geometric accuracy of non-axisymmetric part with stepped feature has been obviously improved, particularly at the stepped feature.