A Mathematical Model for Force Prediction in Single Point Incremental Sheet Forming with Validation by Experiments and Simulation

Incremental sheet forming (ISF) is an emerging technology that has shown great potential in customized three-dimensional (3D) parts without the use of product-specific dies. The force reduced ISF due to localized nature deformation and successive forming. Forming plays important role modeling process accurately, so it needs be evaluated accurately. Some attempts have been made earlier calculate force; however, they are mostly limited empirical formulae for evaluating average its different components. current work presents a mathematical model prediction during 3D polar coordinate system. can used predict forces axis-symmetric cones wall angles also incremental hole flanging. Axial component, resultant r-θ plane, total calculated using developed appearing at depths. cone with same geometrical parameters experimental conditions was modeled simulated on ABAQUS, finally, experiments were carried out six-axis industrial robot. any angle, but comparison purposes, 45° angle analytical, numerical, validation. from had very high level accuracy measured experimentally, maximum error 4.25%. result obtained FEA good calculating force, 4.89%.