Fabrication of a Complicated Specimen with Two Point Incremental Forming Process

Manufacturing of complicated industrial components is one of the main challenges for mechanical engineers in sheet metal forming processes. Incremental sheet metal forming (ISMF) is used widely for forming complicated shapes by a single rotating tool. This paper examines the experimental investigation of two-point incremental forming of a complicated specimen made of AA3105 aluminum alloy. The part shape consists of positive and negative cavities and the shape complexity limits the manufacturing process to two-point incremental forming process (TPIF). In addition, the effects of selected process parameters such as forming depth in each increment of process, tool rotational speed and various forming patterns on thickness distribution and thinning percentage of specimen are investigated. The forming pattern includes the sequence of forming the cavities (Internal/External pattern and External/Internal pattern). The main finding of the study can be expressed that the thinning ratio of manufactured specimen is increased with an increase in the forming depth in each increment of TPIF. Also, the higher rotational speed leads to a reduction in the thinning of the fabricated specimen. The results prove that the use of Internal/External forming pattern leads to reduction in the thinning of the manufactured specimen.