Title: Enhancement in the formability of copper sheet in single point incremental forming process

Authors: Ajay Kumar; Yogesh Kumar; Santosh Kumar; Fariborz Forouhandeh

Addresses: Department of Mechanical Engineering, National Institute of Technology Patna, Patna, Bihar, India ' Department of Mechanical Engineering, National Institute of Technology Patna, Patna, Bihar, India ' Department of Mechanical Engineering, Indian Institute of Technology BHU, Varanasi, Uttar Pradesh, India ' Department of Engineering, Shahrood Branch, Islamic Azad University, Shahrood, Iran

Abstract: Single point incremental forming (SPIF) is a die less flexible manufacturing process capable to produce complex three dimensional components. Die-less nature of the process increases its flexibility, because wide variety of components can be produced by a single tool by altering the process parameters. In SPIF tool movement over workpiece produced localised stress thus formability of material is enhanced. This paper presents experimental results on optimisation of process parameters in SPIF in order to increase formability and dimensional accuracy of formed components. The strategy includes enhancements of materials formability through a localised sheet heating due to stirring action of elevated tool rotational speed and optimisation among tool rotational speed, vertical step size and feed to cause pure plastic deformation which reduces spring back action and pillowing effect of metallic sheet and maximise forming angle. The work is performed on ETP Grade Cu1100 copper sheet.

Keywords: single point incremental forming; SPIF; formability; formability curve.

DOI: 10.1504/IJMATEI.2026.153157

International Journal of Materials Engineering Innovation, 2026 Vol.17 No.2, pp.104 - 116

Received: 20 Mar 2024
Accepted: 04 Aug 2024
Published online: 25 Apr 2026 *

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