Single point incremental sheet forming investigated by in-process 3D digital image correlation

Abstract

Single Point Incremental Forming (SPIF) is a promising sheet metal forming process for prototyping and small batches, in which the blank is formed in a stepwise fashion by a displacement-controlled small-sized tool. Due to specific strain paths induced by the process and limited plastic zones in the contact region between the tool and the workpiece, forming diagrams and forming strategies are different from the classical stamping processes. One major limitation of SPIF is the lack of accuracy of the obtained final parts because of the poor knowledge of the state of stress during the process that requires a good description of the material models and a right choice of the process parameters. In this paper, the SPIF process is experimentally investigated by the mean of surface 3D digital image correlation during the forming of a AW-5086-H111 grade aluminium alloy. Development of strain fields encountered in incremental forming is reported and material formability is evaluated on several formed shapes, taking into account a wide range of straining conditions of this process.