Deformations and forces analysis of single point incremental sheet metal forming

Purpose: In this paper the experimental equipment and design of the system for deformation and forming force measuring by single point incremental sheet metal forming are described. Beside this the analysis results of the impact of the wall angle, tool rotation, vertical step size, tool diameter and lubrication on the magnitude of forming force and plastic logarithmic strain are presented. Design/methodology/approach: The incremental sheet metal forming process was performed on the CNC controlled milling machine Moiri Seiki with the FANUC MSC-521 control system. The forming forces were measured using specially designed force measuring system which is connected with the milling machine. In contrast to force measuring, the deformations of the specimen were measured by using the graphometric analysis based on the size and direction investigation of the major strains of the particular sheet metal area. Findings: The results show that the forming force is very small in comparison to the deep drawing process and it does not depend on the product size. That is why the production of very large products is absolutely appropriate for forming. Beside this, the deformations and forces distribution are mostly dependent on the size of the wall angle of forming, tool diameter and vertical step sizes of the tool. Research limitations/implications: The deformations and forces analyses are researched only for the steel DC05 of 1 mm in thickness. Practical implications: The analysis results will help to improve the choice of the appropriate equipment and to setting of the optimal process parameters on the strain distribution and the size of needed forming force. By this the production time of the product could be reduced, which is otherwise by this process very long. Originality/value: A detailed deformations and forces analyses of single point incremental sheet metal forming for some combinations of process parameters used are original.