A Combined simulation and experimental investigation on tool radius influence on enhancing the formability SPIF process for Al1050 sheet material

Abstract

This research presents a comprehensive investigation into the pioneering domain of single point incremental forming (SPIF), focusing on elucidating the nuanced interplay between tool radius and formability. By employing a combination of rigorous simulation and experimental methodologies, the study sheds light on the pivotal influence of tool radius on forming performance. Various tool radius values spanning from 2 to 7 are systematically tested in conjunction with corresponding forming angles, revealing crucial insights into their synergistic effects. A critical threshold radius (Rt) is discerned, representing the point at which optimal formability is attained. Below this threshold, a decline in formability is observed, attributed to excessive surface cutting and metal pressing phenomena evident in tests utilizing pointed tools. Finite element (FE) analysis corroborates these findings, demonstrating that compression beneath the tool center induces unstable strain, consequently diminishing forming height as tool radius decreases. Conversely, beyond the Rt, an increase in tearing is noted due to reduced compression. This underscores the delicate balance required in selecting an appropriate tool radius to maximize shaping capacity in SPIF processes. Importantly, the research highlights the significance of achieving high compression capacity alongside an optimal tool radius, emphasizing the intricate yet essential factors influencing SPIF’s formability and shaping capabilities. Furthermore, this study contributes to the advancement of SPIF technology by uncovering novel insights into the dynamic relationship between tool geometry and formability, thereby paving the way for enhanced process optimization and design in various manufacturing applications. This research delves into the innovative realm of SPIF by exploring the intricate relationship between tool radius and formability. Through meticulous simulation and experimentation, the study unveils the pivotal role of tool radius in forming performance. The different values of tool radius, ranging from 2 to 7, are coupled with appropriate forming angles. A critical Rt is identified, where optimal formability is achieved. Conversely, below this threshold, formability declines due to excessive surface cutting and metal pressing, observed in tests employing pointed tools. FE analysis substantiates that compression below the tool center triggers unstable strain, diminishing forming height with decreasing tool radius. Notably, above the Rt, an increase in tearing is observed due to decreased compression. In this context, attaining high compression capacity alongside an appropriate tool radius emerges as the key to maximizing shaping capacity in SPIF.