Geometric deviation during incremental sheet forming process: Analytical modeling and experiment

Incremental sheet forming (ISF), a promising and flexible forming method, is generally restricted by the unsatisfied geometric deviation for industrial applications; therefore, effective control and accurate prediction of geometric deviation in ISF are essential for quality improvement. However, the geometric deviation in ISF is extremely sensitive to the geometric shape, toolpath, and process parameters, which is challenging to predict and control. In this study, the comprehensive geometric-related mechanisms in ISF were analyzed, including springback after local bending of the bent and contact zones, and the elastic deflection of the inclined wall, particularly the associated deformation in the weak-stiffness region. Through a creative equivalent mapping method for calculating the elastic deflection of complex structures and modeling the bending moment distribution in different zones, an analytical model was developed to accurately and universally predict the geometric deviations of parts by ISF. Based on the results of the experiments and comparative studies using a response surface model, the proposed model provided superior capability for predicting the geometric accuracies of parts made using ISF with different sheet materials, process parameters, and geometric shapes, even for complex parts with non-axisymmetric structures and stepped features. The geometric-related mechanisms, forming characteristics, and influences of crucial parameters in ISF are discussed by adopting an analytical model combined with numerical simulations, demonstrating that the elastic deflection on the inclined wall, particularly the associated deformation in the weak-stiffness region, plays a primary role in the geometric deviation of complex parts compared with other geometric-related mechanisms.