Experimental Investigation of Incremental Sheet Forming into Complex Geometries Using Aligned Positive and Negative Dies

This study presents an experimental investigation into the incremental sheet forming (ISF) of complex geometries. A two-point ISF setup incorporating both negative and positive dies is utilized to fabricate a part featuring positive and negative truncated cone profiles. The workpiece material used is ۱ mm thick aluminum alloy ۳۱۰۵. The study examines the influence of key process parameters—including the sequence of die usage (positive/negative versus negative/positive), incremental step depth, and tool rotational speed—on the maximum attainable inner and outer heights of the formed part. The tested ranges for step depth and rotational speed are ۰.۲–۰.۶ mm and ۰–۱۰۰۰ rpm, respectively. Experimental findings demonstrate that shifting the forming sequence from positive/negative to negative/positive significantly enhances both outer and inner formability. Additionally, results show that reducing the step depth and increasing the tool’s rotational speed contribute positively to height maximization. Through signal-to-noise ratio analysis, the optimal combination of process parameters is identified as the negative/positive sequence, ۰.۲ mm step depth, and ۱۰۰۰ rpm rotational speed for maximizing both internal and external part dimensions.

کلیدواژه ها:

Two-Point Incremental Sheet Forming (TPISF) ، Aluminum Alloy ، Experimental Design Methodology (DOE)