Optimization of sheet incremental forming process by means of FE simulations

The present paper is the continuation of a research project developed by the Technologies and Manufacturing Systems Group of the University of Brescia and aims to identify the working capabilities and limits of a new sheet forming process, namely Sheet Incremental Forming. The set up for Sheet Incremental Forming is characterized by a general purpose CNC machine equipped with a special tool that progressively deforms the sheet into a negative or positive die. The process can be used to produce prototypes of industrial components, the shell for concrete dies (suitable for low volume batches) or pre-series batches. The research goal is the identification of feasibility limits of this technology, that is the possibility of correctly deforming the pieces without breaking them, by studying a simple square slot. The working parameters analyzed are the tool feed rate, the tool path and the spiral width when working AISI 304 sheets. The aim of this research is to use the experimental results previously obtained to validate a FEM model of the process.