A phenomenology-based approach for modelling material thinning and formability in incremental forming of cylindrical parts

Abstract

Incremental forming processes can be regarded as a promising industrial alternative in future even if many aspects related with the process mechanics are not well explained. In this paper, a variant of the process is presented with the aim of manufacturing cylindrical cups using very simple equipment. This goal can be achieved only with an accurate process design; in fact, material thinning and breaking always constitute a relevant risk. In the present study, an analytical model to predict the thickness distribution in the produced part is proposed. In particular, the model is applied taking into account the most critical zone and determining a correlation between the desired geometry and a very common material formability index. In this way, a preliminary feasibility analysis can be carried out, reducing the process development time. The proposed model was verified by comparing the predicted data with the results of experimental activity.