Title: Improvement in formability of copper sheet in single point incremental forming by combined effects of tool stirring action and optimised forming process parameters

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 Mechanical Engineering, Sha. C., Islamic Azad University, Shahrood, Iran

Abstract: Single point incremental forming (SPIF) is an advanced manufacturing process that has gained popularity in the sheet metal industry. The present work focuses an investigation on stirring action of high rpm of tool on the formability of copper sheet. Copper sheets of grade Cu-1100 of thickness 0.5 mm and 1.0 mm were used as testing materials and deformed incrementally with spindle RPM range from 2,000 to 6,000 with different sets of parameters, and the result found was outstanding. In this investigation maximum forming angle obtained was reached to 80° and 84° for 0.5 mm and 1.0 mm thickness of sheet respectively. Highest forming angle obtained was 84° when forming sheet by SPIF with 0.6 mm step depth, 6,000 rpm spindle speed and 250 mm/min forming speed for 1.0 mm thick copper sheet.

Keywords: single point incremental forming; SPIF; maximum forming angle; maximum forming depth; formability.

DOI: 10.1504/IJMATEI.2026.150693

International Journal of Materials Engineering Innovation, 2026 Vol.17 No.1, pp.21 - 34

Received: 04 Mar 2024
Accepted: 22 Jun 2024
Published online: 22 Dec 2025 *

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