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<p>Double-sided incremental forming (DSIF) provides improved thickness uniformity compared to single point incremental forming (SPIF). However, intermittent loss of counter tool contact still limits dimensional accuracy and formability in complex geometries. This study validates an experimentally supported, finite element (FE), guided adaptive compensation strategy that dynamically adjusts the lower tool trajectory based on spatially varying thickness strain distributions. High-fidelity FE simulations were employed to analyze thickness evolution in SPIF, and localized thinning gradients were extracted to design the compensation toolpath. The proposed strategy was systematically compared with SPIF, DSIF-conventional, and DSIF-sine-law through numerical and experimental investigations. Results show that the DSIF-compensated approach achieves the most uniform stress distribution, reducing peak von Mises stress to 217.5&#xa0;MPa, and limits maximum thickness reduction to 33%, with a minimum thickness of 0.670&#xa0;mm. Experimental thickness profiles closely match numerical predictions, confirming model robustness. The proposed framework effectively stabilizes tool-sheet interaction, suppresses localized thinning, and enhances formability in asymmetric incremental forming applications.</p>

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Numerical Thickness Based Conforming Toolpath Strategy for Double-Sided Incremental Sheet Forming

  • 期刊论文

  • 发表日期：

    2026年5月26日

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  • Gaurav Chaturvedi,
  • Arun Sharma,
  • Parnika Shrivastava

摘要

Double-sided incremental forming (DSIF) provides improved thickness uniformity compared to single point incremental forming (SPIF). However, intermittent loss of counter tool contact still limits dimensional accuracy and formability in complex geometries. This study validates an experimentally supported, finite element (FE), guided adaptive compensation strategy that dynamically adjusts the lower tool trajectory based on spatially varying thickness strain distributions. High-fidelity FE simulations were employed to analyze thickness evolution in SPIF, and localized thinning gradients were extracted to design the compensation toolpath. The proposed strategy was systematically compared with SPIF, DSIF-conventional, and DSIF-sine-law through numerical and experimental investigations. Results show that the DSIF-compensated approach achieves the most uniform stress distribution, reducing peak von Mises stress to 217.5 MPa, and limits maximum thickness reduction to 33%, with a minimum thickness of 0.670 mm. Experimental thickness profiles closely match numerical predictions, confirming model robustness. The proposed framework effectively stabilizes tool-sheet interaction, suppresses localized thinning, and enhances formability in asymmetric incremental forming applications.