Analysis of wall curling in incremental forming of a sheet metal: role of residual stresses, stretching force and process conditions

摘要: Abstract The present work, first detailed study in its nature, introduces wall curl as a source of geometric inaccuracy the novel Incremental Sheet Forming (ISF) process, and aims at investigating role residual stresses, stretching force process conditions on formation curl. A series metal components are formed by varying conditions. height, stresses (surface, mean equivalent) determined their correlations analyzed. analysis reveals that curling is strongly influenced way height increases linearly magnitude increases. Similarly, an increase degree non-uniformity through-thickness stress distribution promotes curling. force, however, diminishes reasoning to reduction stresses. As regard conditions, feed rate does not show any effect while mild annealing, greater tool diameter, smaller step size, lower forming angle rotation found conducive minimize errors bottom produced parts (i.e., pillowing) interesting inverse relationship. reported results very useful deepen mechanics will also prove helpful simultaneously controlling two types errors.