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<p>This study investigates the optimization of thickness distribution, thinning limit, and forming force in the heat-assisted single-point incremental forming (HA-SPIF) of AA1050 aluminum alloy sheets. Although the formability of materials in incremental forming has been widely explored, inconsistencies remain between computational predictions and experimental outcomes. To address this gap, the effects of three key process parameters—forming temperature, tool diameter, and vertical step size—were systematically evaluated using a Taguchi L9 orthogonal array and analysis of variance (ANOVA). The results demonstrate that forming temperature plays a decisive role in enhancing material formability by reducing average forming force, minimizing thickness reduction, and extending the thinning limit. The optimal parameter set—150&#xa0;°C forming temperature, 10&#xa0;mm tool diameter, and 0.5&#xa0;mm step size—yielded the lowest forming force (61.21 N), minimized thickness reduction (26.94%), and achieved the most uniform thickness distribution, with a standard deviation of only 0.0041&#xa0;mm. Compared with room-temperature forming, the thinning limit improved by more than 54%, highlighting the beneficial role of controlled heating in expanding the safe deformation range. This study presents a predictive framework for selecting HA-SPIF parameters to simultaneously optimize thickness uniformity, minimize thinning, and control forming forces. The approach integrates experimental data and mechanistic insights to guide efficient process design for lightweight sheet metals</p>

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Integrated Experimental Study on Thickness Uniformity, Thinning Limit, and Forming Force in Heat-Assisted Single-Point Incremental Forming of AA1050 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2025年12月15日

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  • Trung-Kien Hoang,
  • Thi-Bich Mac,
  • The-Thanh Luyen,
  • Quoc-Tuan Pham,
  • Duc-Toan Nguyen

摘要

This study investigates the optimization of thickness distribution, thinning limit, and forming force in the heat-assisted single-point incremental forming (HA-SPIF) of AA1050 aluminum alloy sheets. Although the formability of materials in incremental forming has been widely explored, inconsistencies remain between computational predictions and experimental outcomes. To address this gap, the effects of three key process parameters—forming temperature, tool diameter, and vertical step size—were systematically evaluated using a Taguchi L9 orthogonal array and analysis of variance (ANOVA). The results demonstrate that forming temperature plays a decisive role in enhancing material formability by reducing average forming force, minimizing thickness reduction, and extending the thinning limit. The optimal parameter set—150 °C forming temperature, 10 mm tool diameter, and 0.5 mm step size—yielded the lowest forming force (61.21 N), minimized thickness reduction (26.94%), and achieved the most uniform thickness distribution, with a standard deviation of only 0.0041 mm. Compared with room-temperature forming, the thinning limit improved by more than 54%, highlighting the beneficial role of controlled heating in expanding the safe deformation range. This study presents a predictive framework for selecting HA-SPIF parameters to simultaneously optimize thickness uniformity, minimize thinning, and control forming forces. The approach integrates experimental data and mechanistic insights to guide efficient process design for lightweight sheet metals