Experimental and Numerical Investigations in Single Point Incremental Sheet Forming

As recent studies introduced Incremental Sheet Forming (ISF) process as a very promising technology to manufacture sheet metal parts by the CNC controlled movement of a simple generative tool, industrial interests on ISF have increased. Indeed, due to its various advantages, such process has been demonstrated as an alternative to reduce costs resulting from stamping technology when small batches or prototypes have to be manufactured. Nevertheless, the process still needs further developments. A process analysis based on experimental and numerical investigations is required to carefully analyze the capabilities of the process and to consolidate its application in sheet metal industries. Starting from experimental results on standard components to show the interest of ISF, an application is carried out accounting flexibility of the process linked to the fact that the punches or dies are avoided and preliminary results have been obtained through experimental tests to manufacture micro parts. At the same time, a FEM analysis has been carried out in order to get the characteristics of the formed parts. In order to study the control of the process, a first study is carried out to perform an on-line sheet thickness measurement.