Title: Formability analysis of AA3003O by optimising processing parameters in single point incremental forming

Authors: Ankita Pandey; Yogesh Kumar

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

Abstract: Incremental sheet forming (ISF) is a die-less process and has various advantages like low tooling cost, part flexibility and higher formability over the conventional sheet forming process. In this work, a robot-based single point incremental sheet forming is carried out. During the forming process, by varying the forming angle from 60° to 75°, the failure of specimen is observed in the truncated pyramid. The mechanism behind the failure is explored and analysed through various (nine) samples which are taken from the successfully formed and failed truncated pyramid parts. It is observed that forming angle of 75° or more causes the crack generation in the metallic sheet. It is also observed that by varying the sheet thickness from 1 mm to 0.5 mm, the maximum forming angle is reduced. It is found that forming angle and step sizes affects the formability of the metallic sheet used in forming process.

Keywords: robot-based incremental sheet forming; formability; forming angle; step sizes; optimisation.

DOI: 10.1504/IJMATEI.2026.155494

International Journal of Materials Engineering Innovation, 2026 Vol.17 No.3, pp.194 - 204

Received: 03 Mar 2024
Accepted: 24 May 2024
Published online: 04 Aug 2026 *

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