Multi-step toolpath approach of improving the dimensional accuracy of a non-axisymmetric part in incremental sheet forming and its mechanism analysis.

Incremental sheet forming (ISF) is a die-less manufacturing technology suitable for small lot and/or customized parts. However, geometric accuracy issues in ISF with a single-step toolpath and a conventional multi-step toolpath, such as the pillow and stepped feature at the base areas of manufactured parts, limit the industrial application of this technology. This study presents a novel parametric multi-step toolpath that uses one additional step to form a non-axisymmetric component with the Al2024 sheet. An acceptable higher geometry accuracy below ± 0.6 mm can be obtained experimentally and numerically by adjusting the influencing factors of the multi-step toolpath. Then, the material motion and the strain path in the forming of the non-axisymmetric component with different multi-step toolpaths is analyzed. Results indicate that the flat base depends on the rigid body motion in the central base area and the strain increment balance between the base and sidewall. [ABSTRACT FROM AUTHOR]

Copyright of Journal of Mechanical Science & Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)