Analysis of Incremental Sheet Forming of Aluminum Alloy

Recent developments in incremental sheet forming have resulted in the creation of novel manufacturing processes that are highly adaptable and could bring significant economic benefits for advanced technologies and low-volume production. In this manuscript, the following variables were examined: the variation in the deformation forces for a part with a pyramidal trunk shape; the variation in the deformations and thinning of the Al 3003 material during the incremental forming process; and the variation in the accuracy of the incrementally formed part and the quality of the surfaces (surface roughness). The components of the forces in the incremental forming have increasing values from the beginning of the process to the maximum value due to the hardening process. The TiN-coated tool ensures lower values of the forming components. Due to the kinematics of the forming process, deviations, especially in shape, from the part in the drawing are observed, which are shown by the radius of curvature of the side wall of the part, the appearance of a radius of connection between the wall and the bottom of the part, as well as dimensional deviations that are expressed by the variation in the forming depth. Concerning the smoothness of the surfaces, it was observed that the best roughness results were obtained in the case of the TiN-coated tool.