The Incremental Sheet Forming of Light Alloys

Abstract

The most recent development in sheet metal industries to produce tailored components in line with customer requirements is incremental sheet forming (ISF). ISF is a die-less sheet metal forming process used to manufacture 3D complex-shaped geometries using simple toolings. The process is carried out in a CNC milling machine or using a robot by inputting the tool path created for the required geometry. A hemispherical forming tool is used to form the sheet metal to the required geometry based on the tool path generated, and the deformation of the sheet metal happens only under the tool region. The process is affected by parameters such as spindle speed, feed rate, pitch size, and tool path; however, ISF drastically improves the formability of the sheet metal compared with conventional sheet forming processes due to the localized deformation. ISF produces complex shapes and sizes of products at very low cost and lead time and is highly suitable for prototyping and batch-type production in industries. Additionally, the process is most advantageous for forming limited formability alloys such as magnesium and titanium, due to their localized plastic deformation. ISF imposes the plane strain and biaxial strain paths, which helps to activate newer deformation systems during the process in these light alloys, thereby improving the room temperature formability of light alloys. Thus, ISF is capable of forming hard-to-deform materials at room temperature without compromising their material properties, which the conventional forming process cannot.