Innovative tool designs to improve formability in case of single point incremental forming

Single point incremental forming (SPIF) is one of the dieless sheet metal forming processes that offer flexibility in the customized fabrication of required parts. Improvement in formability in the case of SPIF has been one of the burning issues in the metal-forming fraternity in the past decades. In the present study, different tool tip geometries, namely hemispherical, elliptical, en-grooved, and triangular tool tips, were employed in the SPIF of 0.8 mm thick CRCA (cold rolled close annealed) steel, and the influence on the forming height was assessed in reference to the commonly used hemispherical tool tip. It was observed that tool geometry has a significant influence on forming height obtained with SPIF, and a maximum of 27% increase in forming height was observed with the en-grooved tool tip with a considerable reduction in the forming force required.