Analysis of the process parameters effect on the thickness distribution and thinning ratio in single point incremental forming process

Incremental forming is a rather innovative process in which sheet metal is formed into complex shapes by stretching the sheet with forming tool whose path is controlled by a computer numerical control machine, this kind of process is suitable for low patch production and customized parts. The blank is fully clamped at its perimeter, so there is no any drawing operation occurs to sheet blank during forming process, therefore an excessive thinning would appear along the wall of the formed parts. Study the influence of some process parameters on the thinning ratio, find suitable parameters to minimize the thinning in single point incremental forming and find some methods to reduce it that is the aim of this research. Ansys workbench software based on finite element method is used to simulate the forming process and analyze the thickness reduction along the wall parts, numerical results are verified experimentally. The results showed the forming angle has great effect while the feed speed has the little effect on the thinning ratio on the formed parts.