Formability Analysis of DC01 Sheet in the Incremental Sheet Forming Method

Abstract

Incremental forming is a new and multipurpose type of prototype manufacturing method where a small forming tool, following a certain tool path, applies localized pressure to a sheet metal. In this study incremental formability of DC01 which widely used in industry is experimentally researched. In the experimental studies, specimens in a shape of frustum cone are formed. Alongside the experimental studies, by using finite element model, sheet thickness variations are investigated. Feedrate, depth of increment and forming tool diameter, which has a direct effect to the limit forming angle and sheet thickness distribution are taken as parameters. In experiments carried out by using 0.5 mm increment and 1000 mm/min feedrate for DC01 sheet with a thickness of 1.18mm, 64 degrees limit forming angle is reached. Corresponding results are compatible with finite element analysis results. Specimen's thickness is reduced by 65% with 64 degrees limit forming angle and minimum sheet thickness of 0.4 mm is achieved.