Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation

  • Parnika Shrivastava
  • Pavan Kumar
  • Puneet TandonEmail author
  • Alexander Pesin
Technical Paper


The work involves finite element analysis (FEA) and experimental investigation of formability and geometrical accuracy prevailing in single point incremental forming (SPIF) process. Preheating at different temperatures was performed in order to reform microstructures (grain size) and texture (spatial grain orientation distribution) of AA1050 sheet. Preheating led to removal and rearrangements of defects in the crystal structure in comparison with the distorted structures present in cold-worked commercial aluminum sheets. Preheating at higher temperatures resulted in coarser grains with preferential texture and increased area fraction of homogenously oriented grains. Numerical simulation of SPIF process has been done to predict the effect of preheating on von Mises stresses, forming load, wall thickness distribution and geometrical accuracy of formed parts. For the purpose, Johnson–Cook models’ parameters were evaluated by mechanical characterization of the samples with varying microstructural and texture arrangements resulted due to variations in preheating temperatures. FEA of the process revealed that preheating of the sheets resulted in reduced forming load, uniform wall thickness distribution and improved geometrical accuracy. The results were further validated by experiments and compared to the original samples with fine and randomly orientated grains.


Single point incremental sheet forming Grain size and orientation Forming load Wall thickness distribution Geometrical accuracy 


  1. 1.
    Mulay A, Ben S, Ismail S, Kocanda A (2017) Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments. J Braz Soc Mech Sci Eng 39:3997–4010. CrossRefGoogle Scholar
  2. 2.
    Pereira Bastos RN, Alves de Sousa RJ, Fernandes Ferreira JA (2016) Enhancing time efficiency on single point incremental forming processes. Int J Mater Form 9:653–662. CrossRefGoogle Scholar
  3. 3.
    Petek A, Kuzman K, Kopaè J (2009) Deformations and forces analysis of single point incremental sheet metal forming. Arch Mater Sci Eng 35:107–116Google Scholar
  4. 4.
    Ambrogio G, Filice L, Micari F (2006) A force measuring based strategy for failure prevention in incremental forming. J Mater Process Technol 177:413–416. CrossRefGoogle Scholar
  5. 5.
    Li Y, Daniel WJT, Liu Z et al (2015) Deformation mechanics and efficient force prediction in single point incremental forming. J Mater Process Technol 221:100–111. CrossRefGoogle Scholar
  6. 6.
    Bansal A, Lingam R, Yadav SK, Venkata Reddy N (2017) Prediction of forming forces in single point incremental forming. J Manuf Process 28:486–493. CrossRefGoogle Scholar
  7. 7.
    Liu Z, Li Y, Meehan PA (2013) Vertical wall formation and material flow control for incremental sheet forming by revisiting multistage deformation path strategies. Mater Manuf Process 28:562–571. CrossRefGoogle Scholar
  8. 8.
    Jiménez I, López C, Martinez-Romero O et al (2017) Investigation of residual stress distribution in single point incremental forming of aluminum parts by X-ray diffraction technique. Int J Adv Manuf Technol 91:2571–2580. CrossRefGoogle Scholar
  9. 9.
    Thibaud S, Ben Hmida R, Richard F, Malécot P (2012) A fully parametric toolbox for the simulation of single point incremental sheet forming process: numerical feasibility and experimental validation. Simul Model Pract Theory 29:32–43. CrossRefGoogle Scholar
  10. 10.
    Li J, Li C, Zhou T (2012) Thickness distribution and mechanical property of sheet metal incremental forming based on numerical simulation. Trans Nonferrous Met Soc China 22:s54–s60. CrossRefGoogle Scholar
  11. 11.
    Cao J, Yao H, Karafillis A, Boyce MC (2000) Prediction of localized thinning in sheet metal using a general anisotropic yield criterion. Int J Plast 16:1105–1129. CrossRefzbMATHGoogle Scholar
  12. 12.
    Hussain G, Gao L, Hayat N (2011) Forming parameters and forming defects in incremental forming of an aluminum sheet: correlation, empirical modeling, and optimization: part A. Mater Manuf Process 26:1546–1553. CrossRefGoogle Scholar
  13. 13.
    Micari F, Ambrogio G, Filice L (2007) Shape and dimensional accuracy in single point incremental forming: state of the art and future trends. J Mater Process Technol 191:390–395. CrossRefGoogle Scholar
  14. 14.
    Min J, Kuhlenkötter B, Shu C et al (2018) Experimental and numerical investigation on incremental sheet forming with flexible die-support from metallic foam. J Manuf Process 31:605–612. CrossRefGoogle Scholar
  15. 15.
    Guo X, Gu Y, Wang H et al (2018) The Bauschinger effect and mechanical properties of AA5754 aluminum alloy in incremental forming process. Int J Adv Manuf Technol 94:1387–1396. CrossRefGoogle Scholar
  16. 16.
    Ai S, Lu B, Chen J et al (2017) Evaluation of deformation stability and fracture mechanism in incremental sheet forming. Int J Mech Sci 124–125:174–184. CrossRefGoogle Scholar
  17. 17.
    Yue ZM, Chu XR, Gao J (2017) Numerical simulation of incremental sheet forming with considering yield surface distortion. Int J Adv Manuf Technol 92:1761–1768. CrossRefGoogle Scholar
  18. 18.
    Do V-C, Pham Q-T, Kim Y-S (2017) Identification of forming limit curve at fracture in incremental sheet forming. Int J Adv Manuf Technol 92:4445–4455. CrossRefGoogle Scholar
  19. 19.
    Benedetti M, Fontanari V, Monelli B, Tassan M (2017) Single-point incremental forming of sheet metals: experimental study and numerical simulation. Proc Inst Mech Eng Part B J Eng Manuf 231:301–312. CrossRefGoogle Scholar
  20. 20.
    Formisano A, Boccarusso L, Capece Minutolo F et al (2017) Negative and positive incremental forming: comparison by geometrical, experimental, and FEM considerations. Mater Manuf Process 32:530–536. CrossRefGoogle Scholar
  21. 21.
    Li Y, Daniel WJT, Meehan PA (2017) Deformation analysis in single-point incremental forming through finite element simulation. Int J Adv Manuf Technol 88:255–267. CrossRefGoogle Scholar
  22. 22.
    Fan G, Gao L (2014) Numerical simulation and experimental investigation to improve the dimensional accuracy in electric hot incremental forming of Ti–6Al–4 V titanium sheet. Int J Adv Manuf Technol 72:1133–1141. CrossRefGoogle Scholar
  23. 23.
    Echrif SBM, Hrairi M (2011) Research and progress in incremental sheet forming processes. Mater Manuf Process 26:1404–1414. CrossRefGoogle Scholar
  24. 24.
    Al-Obaidi A, Kräusel V, Landgrebe D (2016) Hot single-point incremental forming assisted by induction heating. Int J Adv Manuf Technol 82:1163–1171. CrossRefGoogle Scholar
  25. 25.
    Khazaali H, Fereshteh-Saniee F (2018) Application of the Taguchi method for efficient studying of elevated-temperature incremental forming of a titanium alloy. J Braz Soc Mech Sci Eng 40:43. CrossRefGoogle Scholar
  26. 26.
    Kim JH, Lee M-G, Kang J-H, Oh C-S (2017) Crystal plasticity finite element analysis of ferritic stainless steel for sheet formability prediction. Int J Plast 93:26–45. CrossRefGoogle Scholar
  27. 27.
    Khalatbari H, Iqbal A, Shi X et al (2015) High-speed incremental forming process: a trade-off between formability and time efficiency. Mater Manuf Process 30:1354–1363. CrossRefGoogle Scholar
  28. 28.
    De Matteis G, Brando G, Mazzolani FM (2012) Pure aluminium: an innovative material for structural applications in seismic engineering. Constr Build Mater 26:677–686. CrossRefGoogle Scholar
  29. 29.
    Hatch JE, Aluminum Association, American Society for Metals (1984) Aluminum: properties and physical metallurgy. American Society for MetalsGoogle Scholar
  30. 30.
    Roy RK (2014) Recrystallization behavior of commercial purity aluminium alloys. In: Light metal alloys applications. InTechGoogle Scholar
  31. 31.
    Stoudt MR, Levine LE, Creuziger A, Hubbard JB (2011) The fundamental relationships between grain orientation, deformation-induced surface roughness and strain localization in an aluminum alloy. Mater Sci Eng A 530:107–116. CrossRefGoogle Scholar
  32. 32.
    Ducobu F, Rivière-Lorphèvre E, Filippi E (2017) On the importance of the choice of the parameters of the Johnson–Cook constitutive model and their influence on the results of a Ti6Al4V orthogonal cutting model. Int J Mech Sci 122:143–155. CrossRefGoogle Scholar
  33. 33.
    Shrivastava P, Tandon P (2015) Investigation of the effect of grain size on forming forces in single point incremental sheet forming. Proc Manuf 2:41–45. Google Scholar
  34. 34.
    Dwivedi D, Kumar A, Priyadarshi S, et al (2018) Numerical prediction of fracture in parts formed with incremental sheet forming process. pp 173–194Google Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  • Parnika Shrivastava
    • 1
  • Pavan Kumar
    • 1
  • Puneet Tandon
    • 1
    Email author
  • Alexander Pesin
    • 2
  1. 1.Department of Mechanical EngineeringPDPM Indian Institute of Information Technology, Design and Manufacturing, JabalpurJabalpurIndia
  2. 2.Department of Metal FormingNosov State Technical UniversityMagnitogorskRussia

Personalised recommendations