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<p>Single Point Incremental Forming (SPIF) is a flexible sheet metal forming technology, yet its industrial adoption remains limited due to challenges such as excessive wall thinning and premature fracture. This study proposes an integrated experimental–numerical framework to analyze and optimize wall thickness in SPIF of AA1050 aluminum alloy. The Fracture Forming Limit Line (FFL) was established experimentally using truncated conical and pyramidal specimens with varying wall angles, providing reliable failure criteria under the highly localized, non-proportional deformation paths characteristic of SPIF. Material behavior was modeled using the Voce hardening law calibrated along three rolling directions, combined with the Hill’48R anisotropic yield criterion, and implemented in ABAQUS/Explicit. Tool paths were imported directly from G-code, and simulation results were validated against thickness measurements at twelve locations along the generatrix. The model accurately predicted thickness distribution and fracture height, with deviations below 5%. Parametric analysis revealed that vertical step size (<i>t</i><sub><i>z</i></sub>) is the most influential factor on wall thickness (58.6%), followed by feed rate (<i>F</i>, 27.8%) and tool radius (<i>R</i><sub><i>t</i></sub>, 12.5%). The effect of wall angle on formability was quantified, showing that smaller wall angles significantly increase forming height. Optimization using a Taguchi L9 design combined with ANOVA identified an optimal parameter set (<i>R</i><sub><i>t</i></sub> = 5&#xa0;mm, <i>t</i><sub><i>z</i></sub> = 0.5&#xa0;mm, <i>F</i> = 500&#xa0;mm/min), achieving uniform thickness distribution with a minimal simulation–experiment deviation of 1.17%. This work establishes a robust experimental–numerical framework for SPIF of lightweight aluminum sheets, providing theoretical insights and practical guidance for enhancing product quality and manufacturing efficiency.</p>

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Integrated experimental–numerical analysis and optimization of wall thickness in single point incremental forming of AA1050 Aluminum alloy

  • 期刊论文

  • 发表日期：

    2025年11月28日

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  • Duc-Toan Nguyen,
  • Thi-Bich Mac,
  • Trung-Kien Hoang,
  • Thanh-Huan Nguyen,
  • The-Thanh Luyen

摘要

Single Point Incremental Forming (SPIF) is a flexible sheet metal forming technology, yet its industrial adoption remains limited due to challenges such as excessive wall thinning and premature fracture. This study proposes an integrated experimental–numerical framework to analyze and optimize wall thickness in SPIF of AA1050 aluminum alloy. The Fracture Forming Limit Line (FFL) was established experimentally using truncated conical and pyramidal specimens with varying wall angles, providing reliable failure criteria under the highly localized, non-proportional deformation paths characteristic of SPIF. Material behavior was modeled using the Voce hardening law calibrated along three rolling directions, combined with the Hill’48R anisotropic yield criterion, and implemented in ABAQUS/Explicit. Tool paths were imported directly from G-code, and simulation results were validated against thickness measurements at twelve locations along the generatrix. The model accurately predicted thickness distribution and fracture height, with deviations below 5%. Parametric analysis revealed that vertical step size (tz) is the most influential factor on wall thickness (58.6%), followed by feed rate (F, 27.8%) and tool radius (Rt, 12.5%). The effect of wall angle on formability was quantified, showing that smaller wall angles significantly increase forming height. Optimization using a Taguchi L9 design combined with ANOVA identified an optimal parameter set (Rt = 5 mm, tz = 0.5 mm, F = 500 mm/min), achieving uniform thickness distribution with a minimal simulation–experiment deviation of 1.17%. This work establishes a robust experimental–numerical framework for SPIF of lightweight aluminum sheets, providing theoretical insights and practical guidance for enhancing product quality and manufacturing efficiency.