Experimental analysis of several variables influencing formed thickness in two-point incremental forming process

In the current paper, an experimental analysis on Al-sheet (AA 1050) with thickness 0.9 mm to reveal the effect of relevant forming factors on the formed thickness in two-point incremental forming (TPIF) process has been conducted. The formed thickness of pyramid-like shapes was analyzed by studying seven variables: die geometry, tool diameter, tool path, stepover, tool shape, lubricant and slope angle. The proposed analysis utilizes Box-Behnken design of experiment (BBD), main effects plot (MEP) and analysis of variance (ANOVA) for sake of studying the influences of the seven forming factors on the resulted thickness. The results of these analyses have indicated that the most significant factor affecting the formed thickness is the die geometry followed by tool shape, lubricant and stepover respectively for both slope angles of the pyramid. In addition, it has been found that the other variables have also significant effects on the formed thickness at both slopes of the pyramids produced.