Skip to main content
SpringerLink
Account
Menu
Find a journal Publish with us Track your research
Search
Cart
  1. Home
  2. The International Journal of Advanced Manufacturing Technology
  3. Article

Review on the influence of process parameters in incremental sheet forming

  • ORIGINAL ARTICLE
  • Open access
  • Published: 23 February 2016
  • Volume 87, pages 479–499, (2016)
  • Cite this article
Download PDF

You have full access to this open access article

The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript
Review on the influence of process parameters in incremental sheet forming
Download PDF
  • Shakir Gatea1,
  • Hengan Ou1 &
  • Graham McCartney1 

  • 5255 Accesses

  • 130 Citations

  • Explore all metrics

Abstract

Incremental sheet forming (ISF) is a relatively new flexible forming process. ISF has excellent adaptability to conventional milling machines and requires minimum use of complex tooling, dies and forming press, which makes the process cost-effective and easy to automate for various applications. In the past two decades, extensive research on ISF has resulted in significant advances being made in fundamental understanding and development of new processing and tooling solutions. However, ISF has yet to be fully implemented to mainstream high-value manufacturing industries due to a number of technical challenges, all of which are directly related to ISF process parameters. This paper aims to provide a detailed review of the current state-of-the-art of ISF processes in terms of its technological capabilities and specific limitations with discussions on the ISF process parameters and their effects on ISF processes. Particular attention is given to the ISF process parameters on the formability, deformation and failure mechanics, springback and accuracy and surface roughness. This leads to a number of recommendations that are considered essential for future research effort.

Article PDF

Download to read the full article text

Similar content being viewed by others

A review on the recent development of incremental sheet-forming process

Article 03 April 2017

Recent Investigations on Incremental Sheet Forming: From Fundamentals to Industrial Application Technologies

Chapter © 2021

Review on strategies for geometric accuracy improvement in incremental sheet forming

Article 15 February 2019

Explore related subjects

Discover the latest articles, news and stories from top researchers in related subjects.
  • Artificial Intelligence
Use our pre-submission checklist

Avoid common mistakes on your manuscript.

References

  1. Hirt G, Bambach M (2012) Incremental Sheet Forming. In: Altan T, Tekkaya AE (eds) Sheet metal forming: processes and applications. ASM International, Materials Park, Ohio

    Google Scholar 

  2. Myoung-Sup S, Jong-Jin P (2001) The formability of aluminum sheet in incremental forming. J Mater Process Technol 113:654–658

    Article  Google Scholar 

  3. Tisza M (2012) General overview of sheet incremental forming. JAMME 55/1:113–120

    Google Scholar 

  4. Leszak, E. (1967). Apparatus and process for incremental dieless forming United states patent office.

  5. Mason, B. (1978). Sheet metal forming small batches. Bachelor's thesis, University of Nottingham.

  6. Appleton E, Mason B (1984) Sheetmetal forming for small batches using sacrificial tooling. Production Eng 63(9):58–61

    Article  Google Scholar 

  7. Hagan E, Jeswiet J (2003) A review of conventional and modern single-point sheet metal forming methods. J Eng Manuf 217 Part B:213–225

    Article  Google Scholar 

  8. Jeswiet J, Micari F, Hirt G, Bramley A, Duflou J, Allwood J (2005) Asymmetric single point incremental forming of sheet metal. CIRP Ann Manuf Technol 54(2):88–114

    Article  Google Scholar 

  9. 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(1-3):390–395

    Article  Google Scholar 

  10. Emmens WC, van den Boogaard AH (2009) An overview of stabilizing deformation mechanisms in incremental sheet forming. J Mater Process Technol 209(8):3688–3695

    Article  Google Scholar 

  11. Emmens WC, Sebastiani G, van den Boogaard AH (2010) The technology of Incremental Sheet Forming—a brief review of the history. J Mater Process Technol 210(8):981–997

    Article  Google Scholar 

  12. Taleb Araghi B, Göttmann A, Bambach M, Hirt G, Bergweiler G, Diettrich J, Steiners M, Saeed-Akbari A (2011) Review on the development of a hybrid incremental sheet forming system for small batch sizes and individualized production. Prod Eng 5(4):393–404

    Article  Google Scholar 

  13. Lora FA, Boff U, Yurgel CC, Folle LF, Schaeffer L (2013) Validation of the computer simulation process applied to the incremental forming process for the evaluation of strain paths. Key Eng Mater 554–557:2453–2461

    Article  Google Scholar 

  14. Attanasio A, Ceretti E, Giardini C, Mazzoni L (2008) Asymmetric two points incremental forming: improving surface quality and geometric accuracy by tool path optimization. J Mater Process Technol 197(1-3):59–67

    Article  Google Scholar 

  15. Jeswiet J, Young D (2005) Forming limit diagrams for single-point incremental forming of aluminium sheet. Proc Inst Mech Eng B J Eng Manuf 219(4):359–364

    Article  Google Scholar 

  16. Verbert J, Belkassem B, Henrard C, Habraken A, Gu J, Sol H, Lauwers B, Duflou J (2008) Multi-Step toolpath approach to overcome forming limitations in single point incremental forming. Int J Mater Form 1(1):1203–1206

    Article  Google Scholar 

  17. Luigino F, Giusy A, Manlio G (2013) Optimised tool-path design to reduce thinning in incremental sheet forming process. Int J Mater Form 6:173–178

    Article  Google Scholar 

  18. Schaeffer, L., Castelan, J., Gruber, V., Daleffe, A., & Marcelino, R. development of customized products through the use of incremental sheet forming for medical orthopadic application. 3rd International Conference on Integrity, Reliability and Failure, Porto/Portugal, 2009(Paper Ref: S0209_P0308): p. 1-12.

  19. Decultot N, Robert L, Velay V, Bernhart G (2010) Single point incremental sheet forming investigated by in-process 3D digital image correlation. EPJ Web Conf 6:11001

    Article  Google Scholar 

  20. Martins PAF, Bay N, Atkins AG, Skjoedt M, Silva MB (2008) Single‐point incremental forming and formability–failure diagrams. J Strain Anal Eng Design 43(1):15–35

    Article  Google Scholar 

  21. Allwood JM, Shouler DR, Tekkaya AE (2007) The increased forming limits of incremental sheet forming processes. Key Eng Mater 344:621–628

    Article  Google Scholar 

  22. Silva MB, Skjoedt M, Martins PAF, Bay N (2008) Revisiting the fundamentals of single point incremental forming by means of membrane analysis. Int J Mach Tool Manu 48:73–83

    Article  Google Scholar 

  23. Saad A (2012) Single point incremental point, in Department of Industrial Engineering And Production. Kth Royal Institute of Technology, Stockholm, Sweden

    Google Scholar 

  24. Kim TJ, Yang DY (2000) Improvement of formability for the incremental sheet metal forming process. Int J Mech Sci 42:1271–1286

    Article  MATH  Google Scholar 

  25. Han F, Mo J-h (2008) Numerical simulation and experimental investigation of incremental sheet forming process. J Cent S Univ Technol 15(5):581–587

    Article  Google Scholar 

  26. Jun-chao L, Chong L, Zhou T-g (2012) Thickness distribution and mechanical property of sheet metal incremental forming based on numerical simulation. Trans Nonferrous Metals Soc China 22:s54–s60

    Article  Google Scholar 

  27. Junchao L, Jianbiao H, Junjie P, Pei G (2012) Thickness distribution and design of a multi-stage process for sheet metal incremental forming. Int J Adv Manuf Technol 62:981–988

    Article  Google Scholar 

  28. Junchao L, Geng P, Shen J (2013) Numerical simulation and experimental investigation of multistage incremental sheet forming. Int J Adv Manuf Technol 68(9-12):2637–2644

    Article  Google Scholar 

  29. Silva PJ, Leodido LM, Silva CRM (2013) Analysis of incremental sheet forming parameters and tools aimed at rapid prototyping. Key Eng Mater 554–557:2285–2292

    Article  Google Scholar 

  30. Duflou JR, Callebaut B, Verbert J, De Baerdemaeker H (2007) Laser assisted incremental forming: formability and accuracy improvement. CIRP Ann Manuf Technol 56(1):273–276

    Article  Google Scholar 

  31. Ji YH, Park JJ (2008) Formability of magnesium AZ31 sheet in the incremental forming at warm temperature. J Mater Process Technol 201(1-3):354–358

    Article  Google Scholar 

  32. Fan G, Gao L, Hussain G, Wu Z (2008) Electric hot incremental forming: a novel technique. Int J Mach Tools Manuf 48(15):1688–1692

    Article  Google Scholar 

  33. Liu, R., Lu B., Xu D., Chen, J., Chen, F., Ou, H., Long, H. (2015). Development of novel tools for electricity-assisted incremental sheet forming of titanium alloy. Int J Adv Manuf Tech, in-press, p. 1-8.

  34. Göttmann A, Diettrich J, Bergweiler G, Bambach M, Hirt G, Loosen P, Poprawe R (2011) Laser-assisted asymmetric incremental sheet forming of titanium sheet metal parts. Prod Eng 5(3):263–271

    Article  Google Scholar 

  35. Mosecker L, Göttmann A, Saeed-Akbari A, Bleck W, Bambach M, Hirt G (2013) Deformation mechanisms of Ti6Al4V sheet material during the incremental sheet forming with laser heating. Key Eng Mater 549:372–380

    Article  Google Scholar 

  36. Adams D, Jeswiet J (2014) Single-point incremental forming of 6061-T6 using electrically assisted forming methods. J Eng Manuf 228(7):757–764

    Article  Google Scholar 

  37. Ham M, Jeswiet J (2006) Single point incremental forming and the forming criteria for AA3003. CIRP Ann Manuf Technol 55(1):241–244

    Article  Google Scholar 

  38. Minutolo FC, Durante M, Formisano A, Langella A (2007) Evaluation of the maximum slope angle of simple geometries carried out by incremental forming process. J Mater Process Technol 194(1-3):145–150

    Article  Google Scholar 

  39. Bhattacharya A, Maneesh K, Venkata Reddy N, Cao J (2011) Formability and surface finish studies in single point incremental forming. J Manuf Sci Eng 133(6):061020

    Article  Google Scholar 

  40. Radu C (2011) Determination of the maximum forming angle of some carbon steel metal sheet. J Eng Stud Res 17:71–74

    Google Scholar 

  41. Fritzen D, Daleffe A, Castelan J, Schaeffer L (2013) Brass 70/30 and incremental sheet forming process. Key Eng Mater 554–557:1419–1431

    Article  Google Scholar 

  42. Ambrogio, G., L. Filice, L., Fratini, and Micari, F. (2004). Process mechanics analysis in single point incremental forming. in MATERIALS PROCESSING AND DESIGN: Modeling, Simulation and Applications-NUMIFORM 2004-Proceedings of the 8th International Conference on Numerical Methods in Industrial Forming Processes. AIP Publishing 712(1) p.922-927.

  43. Kim YS, Lee HJ, Park JG, Nguyen DT (2010) Finite element method study of incremental sheet forming for complex shape and its improvement. Proc Inst Mech Eng B J Eng Manuf 224(6):913–924

    Article  Google Scholar 

  44. Hussain G, Gao L, Zhang ZY (2008) Formability evaluation of a pure titanium sheet in the cold incremental forming process. Int J Adv Manuf Technol 37:920–926

    Article  Google Scholar 

  45. Duflou J, Tunçkol Y, Szekeres A, Vanherck P (2007) Experimental study on force measurements for single point incremental forming. J Mater Process Technol 189(1-3):65–72

    Article  Google Scholar 

  46. Rattanachan K, Chungchoo C (2009) Formability in single point incremental forming of dome geometry. AIJSTPME 2(4):57–63

    Google Scholar 

  47. Buffa G, Campanella D, Fratini L (2013) On the improvement of material formability in SPIF operation through tool stirring action. Int J Adv Manuf Technol 66(9-12):1343–1351

    Article  Google Scholar 

  48. Ham M, Jeswiet J (2007) Forming limit curves in single point incremental forming. CIRP Ann Manuf Technol 56(1):277–280

    Article  Google Scholar 

  49. Lu B, Fang Y, Xu D, Chen J, Ou H, Moser N, Cao J (2014) Mechanism investigation of friction-related effects in single point incremental forming using a developed oblique roller-ball tool. Int J Mach Tools Manuf 85:14–29

    Article  Google Scholar 

  50. Yamashita M, Gotoh M, Atsumi S-Y (2008) Numerical simulation of incremental forming of sheet metal. J Mater Process Technol 199(1-3):163–172

    Article  Google Scholar 

  51. Zhou LR (2011) Study on mechanism of NC sheet metal incremental forming. Adv Mater Res 239–242:940–943

    Article  Google Scholar 

  52. Azaouzi M, Lebaal N (2012) Tool path optimization for single point incremental sheet forming using response surface method. Simul Model Pract Theory 24:49–58

    Article  Google Scholar 

  53. Liu Z, Li Y, Meehan PA (2013) Experimental investigation of mechanical properties, formability and force measurement for AA7075-O aluminum alloy sheets formed by incremental forming. Int J Precis Eng Manuf 14(11):1891–1899

    Article  Google Scholar 

  54. SY, L.V. (2009). Modeling of single point incremental forming process for metal and polymeric sheet in Department of Innovation in Mechanics and Management. PhD thesis, University of Padova.

  55. Martins PAF, Bay N, Skjoedt M, Silva MB (2008) Theory of single point incremental forming. CIRP Ann Manuf Technol 57(1):247–252

    Article  Google Scholar 

  56. SIMULIA, ABAQUS 6.13, Alalysis User's Manual. 2013.

  57. Jackson K, Allwood J (2009) The mechanics of incremental sheet forming. J Mater Process Technol 209(3):1158–1174

    Article  Google Scholar 

  58. Malhotra, R., Xue, L., Cao, J., and Belytschko, T. (2011). Identification of Deformation Mechanisms Responsible for Failure in Incremental Forming using a Damage Based Fracture Model. Proc. Numisheet2011 conf, Seoul, South Korea,p. 469-476.

  59. Malhotra R, Xue L, Belytschko T, Cao J (2012) Mechanics of fracture in single point incremental forming. J Mater Process Technol 212(7):1573–1590

    Article  Google Scholar 

  60. Guzmán CF, Habraken AM (2013) Towards fracture prediction in single point incremental forming. Key Eng Mater 554–557:2355–2362

    Article  Google Scholar 

  61. Xu, D., Malhotra, R., Chen, J., Lu, B., and Cao J. (2013). Numerical and experimental studies for the effects of through-the-thickness shear on formability in single point incremental forming. AIP Conf Proc, p. 969-976.

  62. Fang Y, Lu B, Chen J, Xu DK, Ou H (2014) Analytical and experimental investigations on deformation mechanism and fracture behavior in single point incremental forming. J Mater Process Technol 214(8):1503–1515

    Article  Google Scholar 

  63. Câmara, J.L.P.d.B., (2009). Single Point Incremental Forming, in Engenharia Mecânica. MSc thesis, Danmarks Tekniske Universitet.

  64. Han HN, Kim K-H (2003) A ductile fracture criterion in sheet metal forming process. J Mater Process Technol 142(1):231–238

    Article  Google Scholar 

  65. Araujo, R., P. Teixeira, L. Montanari, A. Reis, M.B. Silva, and P.A. Martins. (2013). Single point incremental forming of a facial implant. Prosthet Orthot Int 38(5):369-78.

  66. Nguyen D-T, Kim Y-S (2013) A numerical study on establishing the forming limit curve and indicating the formability of complex shape in incremental sheet forming process. Int J Precis Eng Manuf 14(12):2087–2093

    Article  Google Scholar 

  67. Centeno G, Martínez-Donaire AJ, Vallellano C, Martínez-Palmeth LH, Morales D, Suntaxi C, García-Lomas FJ (2013) Experimental study on the evaluation of necking and fracture strains in sheet metal forming processes. Procedia Engineering 63:650–658

    Article  Google Scholar 

  68. Isik K, Silva MB, Tekkaya AE, Martins PAF (2014) Formability limits by fracture in sheet metal forming. J Mater Process Technol 214(8):1557–1565

    Article  Google Scholar 

  69. Valentin SO, Adrian MP, Cristian VD, Radu F, Mihai R (2009) Numerical simulation of the incremental forming process for knee implants. X International Conference on Computational Plasticity, CIMNE, Barcelona, pp 1–4

    Google Scholar 

  70. Oleksik V, Pascu A, Deac C, Fleaca R, Roman M, Bologa O (2010) The influence of geometrical parameters on the incremental forming process for knee implants analyzed by numerical simulation. NUMIFORM 2010:1208–1215

    Google Scholar 

  71. Silva MB, Nielsen PS, Bay N, Martins PAF (2011) Failure mechanisms in single-point incremental forming of metals. Int J Adv Manuf Technol 56(9-12):893–903

    Article  Google Scholar 

  72. Centeno G, Bagudanch I, Martínez-Donaire AJ, García-Romeu ML, Vallellano C (2014) Critical analysis of necking and fracture limit strains and forming forces in single-point incremental forming. Mater Des 63:20–29

    Article  Google Scholar 

  73. Ambrogio G, Costantino I, De Napoli L, Filice L, Fratini L, Muzzupappa M (2004) Influence of some relevant process parameters on the dimensional accuracy in incremental forming: a numerical and experimental investigation. J Mater Process Technol 153–154:501–507

    Article  Google Scholar 

  74. Dejardin S, Thibaud S, Gelin JC, Michel G (2010) Experimental investigations and numerical analysis for improving knowledge of incremental sheet forming process for sheet metal parts. J Mater Process Technol 210(2):363–369

    Article  Google Scholar 

  75. Han F, Mo J-h, Gong P, Li M (2011) Method of closed loop springback compensation for incremental sheet forming process. J Cent S Univ Technol 18(5):1509–1517

    Article  Google Scholar 

  76. Hartley KEP (2011) An assessment of various process strategies for improving precision in single point incremental forming. Int J Mater Form 4:401–412

    Article  Google Scholar 

  77. Gong ZFJMFHP (2013) Tool path correction algorithm for single-point incremental forming of sheet metal. Int J Adv Manuf Technol 64:1239–1248

    Article  Google Scholar 

  78. Lu B, Chen J, Ou H, Cao J (2013) Feature-based tool path generation approach for incremental sheet forming process. J Mater Process Technol 213(7):1221–1233

    Article  Google Scholar 

  79. Mehdi V, Mohammad S, Hossein K (2010) An analytical model to reduce spring-back in incremental sheet metal forming (ISMF) process. Adv Mater Res 83–86:1113–1120

    Google Scholar 

  80. Pohlak, M., Küttner, R., Majak, J., Karjust, K., and Sutt, A. (2004). experimental study of incremental forming of sheet metal product. 4th International DAAAM Conference, (Inddustrial Engineering-Innovation as competitve Edge for SMES): Tallinn, Estonia, Citeseer, p. 139-142.

  81. Cerro I, Maidagan E, Arana J, Rivero A, Rodríguez PP (2006) Theoretical and experimental analysis of the dieless incremental sheet forming process. J Mater Process Technol 177(1-3):404–408

    Article  Google Scholar 

  82. Durante M, Formisano A, Langella A, Capece Minutolo FM (2009) The influence of tool rotation on an incremental forming process. J Mater Process Technol 209(9):4621–4626

    Article  Google Scholar 

  83. Hamilton K, Jeswiet J (2010) Single point incremental forming at high feed rates and rotational speeds: surface and structural consequences. CIRP Ann Manuf Technol 59:311–314

    Article  Google Scholar 

  84. Ham M, Powers BM, Loiselle J (2013) Surface topography from single point incremental forming using an acetal tool. Key Eng Mater 549:84–91

    Article  Google Scholar 

  85. Oleksik V, Pascu A, Deac C, Fleacă R, Bologa O, Racz G (2010) Experimental study on the surface quality of the medical implants obtained by single point incremental forming. Int J Mater Form 3(S1):935–938

    Article  Google Scholar 

  86. Skjoedt M, Hancock MH, Bay N (2007) Creating helical tool paths for single point incremental forming. Key Eng Mater 344:583–590

    Article  Google Scholar 

  87. Hagan E, Jeswiet J (2004) Analysis of surface roughness for parts formed by computer numerical controlled incremental forming. J Eng Manuf 218(Part B):1307–1312

    Article  Google Scholar 

  88. Ambrogio G, Filice L, Gagliardi F (2012) Formability of lightweight alloys by hot incremental sheet forming. Mater Des 34:501–508

    Article  Google Scholar 

  89. Daleffe A, Schaeffer L, Fritzen D, Castelan J (2013) Analysis of the incremental forming of titanium F67 grade 2 sheet. Key Eng Mater 554–557:195–203

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical, Materials and Manufacturing Engineering, Faculty of Engineering, University of Nottingham, Nottingham, NG7 2RD, UK

    Shakir Gatea, Hengan Ou & Graham McCartney

Authors
  1. Shakir Gatea
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hengan Ou
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Graham McCartney
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Shakir Gatea.

Rights and permissions

Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gatea, S., Ou, H. & McCartney, G. Review on the influence of process parameters in incremental sheet forming. Int J Adv Manuf Technol 87, 479–499 (2016). https://doi.org/10.1007/s00170-016-8426-6

Download citation

  • Received: 22 October 2015

  • Accepted: 25 January 2016

  • Published: 23 February 2016

  • Issue Date: October 2016

  • DOI: https://doi.org/10.1007/s00170-016-8426-6

Share this article

Anyone you share the following link with will be able to read this content:

Sorry, a shareable link is not currently available for this article.

Provided by the Springer Nature SharedIt content-sharing initiative

Keywords

  • Single-point incremental forming
  • Formability
  • Failure mechanisms
  • Springback
  • Surface roughness
Use our pre-submission checklist

Avoid common mistakes on your manuscript.

Advertisement

Search

Navigation

  • Find a journal
  • Publish with us
  • Track your research

Discover content

  • Journals A-Z
  • Books A-Z

Publish with us

  • Publish your research
  • Open access publishing

Products and services

  • Our products
  • Librarians
  • Societies
  • Partners and advertisers

Our imprints

  • Springer
  • Nature Portfolio
  • BMC
  • Palgrave Macmillan
  • Apress
  • Your US state privacy rights
  • Accessibility statement
  • Terms and conditions
  • Privacy policy
  • Help and support
  • Cancel contracts here

Not affiliated

Springer Nature

© 2024 Springer Nature