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<p>In two-point incremental forming (TPIF), the target geometry is obtained by the contemporary deformation caused by tool movement on the sheet surface and the sheet stretching by the machine frame load. Previously, the sheet deformation due to the tool movement was extensively investigated; however, the frame load effect has not been considered. This study focuses on the increasing frame loads effect (500&#xa0;N to 5000 N) on the aluminum alloy sheet thickness distribution, geometric precision, forming force reduction, plastic strain, and von Mises stress based on experiments and numerical analyses while keeping the remaining process and material parameters constant for pyramid and complex components. The geometric precision for the target region was less affected by the increasing frame loads in both geometries. For the pyramid, frame loads from 500&#xa0;N–2700 N resulted in uniform sheet thickness along the entire component. For the complex component, an optimal frame load of 3350 N resulted in uniform sheet thickness. A slight variation from the optimal frame load resulted in non-uniform sheet thickness distribution. The required tool forming force decreases with an increasing frame load. This study will help bring this vital factor into the mainstream to be investigated along with other process parameters to have a comprehensive approach for a swift breakthrough in overcoming the process’s shortcomings.</p>

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Frame load effect on forming quality in two-point incremental forming

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • Sattar Ullah,
  • Li Xiaoqiang,
  • Li Yanle,
  • Ghulam Hussain,
  • Dong Hongrui,
  • Naseem Ahmad,
  • Mohammed Alkahtani,
  • Hafiz Ejaz Ahmad,
  • Li Dongsheng

摘要

In two-point incremental forming (TPIF), the target geometry is obtained by the contemporary deformation caused by tool movement on the sheet surface and the sheet stretching by the machine frame load. Previously, the sheet deformation due to the tool movement was extensively investigated; however, the frame load effect has not been considered. This study focuses on the increasing frame loads effect (500 N to 5000 N) on the aluminum alloy sheet thickness distribution, geometric precision, forming force reduction, plastic strain, and von Mises stress based on experiments and numerical analyses while keeping the remaining process and material parameters constant for pyramid and complex components. The geometric precision for the target region was less affected by the increasing frame loads in both geometries. For the pyramid, frame loads from 500 N–2700 N resulted in uniform sheet thickness along the entire component. For the complex component, an optimal frame load of 3350 N resulted in uniform sheet thickness. A slight variation from the optimal frame load resulted in non-uniform sheet thickness distribution. The required tool forming force decreases with an increasing frame load. This study will help bring this vital factor into the mainstream to be investigated along with other process parameters to have a comprehensive approach for a swift breakthrough in overcoming the process’s shortcomings.