Investigating the Fracture Height-Wall Angle Relationship in Single-Point Incremental Forming of Al1050 Aluminum Sheets: An Experimental Study

This study examines the effect of toolpath types and wall angles on the formability of Al1050 aluminum sheets in the single-point incremental forming (SPIF) process. The results indicate that a continuous tool movement direction improves the deformation ability of the part compared to reversing the tool movement after each down step. The wall angle experiments reveal that for angles less than 60°, the workpiece does not fracture and has almost unlimited formability. However, when the wall angle is greater than 64°, the fracture height of the workpiece experiences a sudden change at a punch stroke of 28 mm. The fracture height gradually decreases as the wall angle increases to 90°. These findings provide a recommended design limit for parts made from Al1050 aluminum sheets in the SPIF process.