Single point incremental forming at high feed rates and rotational speeds: Surface and structural consequences

Effects of forming at high feed rates and tool rotational speeds were studied and analyzed in single point incremental forming (SPIF). Parts formed were examined on the following criteria: external non-contact surface roughness (orange peel effect), thickness distribution and sectional microstructure. Ra and Rz roughness and forming parameters were used to create models for an equivalent combinatory roughness which characterizes orange peel roughening. Equivalent roughness shows strong sensitivity to a defined shape factor and the forming step size. Effective roughness ranges are established with conditions for which they valid. Thickness distribution and grain structure remains similar to lower speed forming.