Optimization of Process Parameters on Forming Limit of Sheet Metal Components by Using Single-Point Incremental Metal Forming

Using a punch (or other tool), the sheet metal is gradually deformed during the single-point incremental sheet metal forming process. The back of the sheet may or may not be supported during the process of gradual deformation. Dieless sheet formation is influenced by a multitude of process parameters. This work aims to determine how tool geometry affects sheet metal component formability when single-point incremental sheet metal forming is used. Many tests using three distinct tools—a ball nose tool, an elliptical shape forming tool tip with a plane diameter, and an elliptical shape tool tip with a tapered shank—have been conducted for this purpose. A strong correlation has been seen between the simulation and the experimental work, and the full exercise has also been replicated in a virtual setting. It has been noted that the analysis’s findings would aid in better tool selection and the acquisition of superior forming limits corresponding to the particular sheet metal component.