Incremental forming processes can be regarded as a promising industrial alternative in future even if many aspects related with the process mechanics are not well explained. In this paper, a variant of the process is presented with the aim of manufacturing cylindrical cups using very simple equipment. This goal can be achieved only with an accurate process design; in fact, material thinning and breaking always constitute a relevant risk. In the present study, an analytical model to predict the thickness distribution in the produced part is proposed. In particular, the model is applied taking into account the most critical zone and determining a correlation between the desired geometry and a very common material formability index. In this way, a preliminary feasibility analysis can be carried out, reducing the process development time. The proposed model was verified by comparing the predicted data with the results of experimental activity.
IsekiH.KatoK.SakamotoS.Flexible and incremental sheet metal bulging using a pathcontrolled spherical roller. Trans. Japan Soc. Mech. Engrs, Ser. C, 1992, 58(554), 3147–3155.
2.
MatsubaraS.Incremental backward forming of a sheet metal with a hemispherical head tool. J. Japan Soc. Technol. Plasticity, 1994, 35, 1311–1321.
3.
SawadaT.MatsubaraS.SakamotoM.FukuharaG.Deformation analysis for stretch forming of sheet metal with CNC machine tool. In Advanced technology of plasticity 1999, Proceedings of the Sixth Conference on Technology of plasticity, 1999 pp. 1501–1504 (Springer, Nuremberg).
4.
JeswietJ.MicariF.HirtG.BramleyA.DuflouJ.AllwoodJ.Asymmetric single point incremental forming of sheet metal. Ann. CIRP, 2005, 54(1), 623–650.
5.
FiliceL.FratiniL.MicariF.Analysis of material formability in incremental forming. Ann. CIRP, 2002, 51(1), 199–202.
6.
KimT.J.YangD.Y.Improvement of formability for the incremental sheet metal forming process. Int. J. Mech. Sci., 2001, 42, 1271–1286.
7.
HaganE.JeswietJ.A review of conventional and modern single point sheet metal forming methods. Proc. Instn Mech. Engrs, Part B: J. Engineering Manufacture, 2003, 217, 213–225.
8.
ShimM.-S.ParkJ. J.The formability of aluminum sheet in incremental forming. J. Mater. Process Technol., 2001, 113, 654–658.
9.
KitazawaK.NakajimaA.Method for producing aluminium cylindrical shell having uniform wallthickness by CNC incremental forming process. J. Japan Inst. Light Metals, 1997, 47, 378–384.
10.
KitazawaK.NakajimaA.Rupture phenomena in cylindrical incremental drawing of aluminium sheets. J. Japan Inst Light Metals, 1999, 49, 72–76.
11.
YoungD.JeswietJ.Wall thickness variation in single point incremental forming. Proc. Instn Mech. Engrs, Part B: J. Engineering Manufacture, 2004, 218, 1453–1459.
12.
AminoH.LuY.MakyT.OsawaS.FukudaK.Dieless NC forming, prototype of automotive service parts. In Proceedings of the Second International Conference on Rapid prototyping and manufacturing (ICRPM), Tsinghau University Press Beijing, PR China, 2002.
13.
AmbrogioG.De NapoliL.FiliceL.GagliardiF.MuzzupappaM.Application of incremental forming process for high customised medical product manufacturing. J. Mater. Process Technol., 2005, 162–163, 156–162.
14.
HirtG.AmesJ.BambachM.A new forming strategy to realise parts designed for deep-drawing by incremental CNC sheet forming. Int. J. Steel Res., 2005, 76(2–3), 160–166.
15.
KitazawaK.NakajimaA.Cylindrical incremental drawing of sheet metals by CNC incremental forming process. In Advanced technology of plasticity 1999, Proceedings of the Sixth International Conference on Technology of Plasticity, 1999, pp. 1495–1500 (Springer, Nuremberg).
YoungD.JeswietJ.Forming limit diagrams for single point incremental forming of aluminium sheet. Proc. Instn Mech. Engrs, Part B: J. Engineering Manufacture, 2003, 217, 204–210.
18.
IsekiH.A simple deformation analysis for incremental bulging of sheet metal using high speed water jet. In Advanced technology of plasticity 1999, Proceedings of the 6th Conference on technology of plasticity, Nuremberg, 1999, pp. 1483–1488.
19.
AmbrogioG.FiliceL.GagliardiF.MicariF.Sheet thinning prediction in single point incremental forming. Advd Mater. Res., 2005, 6-8, 479–486.
20.
FratiniL.AmbrogioG.Di LorenzoR.FiliceL.MicariF.Influence of mechanical properties of the sheet material on formability in single point incremental forming. Ann. CIRP, 2004, 53(1), 207–210.
21.
IsekiH.An experimental and theoretical study on a forming limit curve in incremental forming of sheet metal using spherical roller. In Proceedings of the Conference on Metal forming, 2000, pp. 557–562 (Balkema, Krakow).
