The electricity assisted incremental sheet forming (E-ISF) is a new flexible forming method, which could further widen the application of the incremental sheet forming (ISF) process on conventional 'hard-to-form' materials such as titanium alloy Ti6Al4V.However, in the E-ISF process, challenges remain in the rough surface finish of formed parts and severe tool wear. To overcome this problem, various novel tools have been designed for the improvement of surface quality in this paper. To validate the designed tools, experiments were conducted on hot ISF of Ti6Al4V sheets with an initial thickness of 1 mm. By comparing the tool temperature and the surface finish, different tools were evaluated. The result suggests that by introducing a design for water cooling, tool wear can be reduced whilst the surface finish can be improved by employing a roller ball at the tool tip.
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