Incremental sheet forming is a dieless forming process. Innovative analysis of
deformations in the SPIF process, utilizing four distinct sets of deformed
structures. Each set consists of four deformed shapes that are categorized as
constant and variable tool path, as well as process characteristics including
deformed shape, spindle speed, step size, and feed rate. The objective of this
article is to investigate the variation of forming force, surface roughness,
hardness value, strain rate, forming limit curve (FLC), and strain against
forming depth and is to optimize its process parameters. Pyramid frustums have a
lower surface roughness than conical frustums. Deformation depth affects
hardness at different points along the frustum. The hardness value of the
pyramid frustum is often higher than that of the conical frustum. As no single
parameter is demonstrated to be significant in determining strain rate, the
deformed shape is more relevant than the other process parameters. This effect
is observed in the cone and pyramid frustums, where the cone frustum exhibits a
higher strain rate than the pyramid frustum at a constant and variable wall
angle. The result parameters increase; variation in decrease; variation in
increase, and decline for different deformed shapes CWACF-1, 2, 3, 4, CWAPF-1,
2, 3, 4, VWACF-1, 2, 3, 4 and VWAPF-1, 2, 3, 4, respectively, under different
other process parameters. The strain rate must not exceed the FLC to prevent
sheet fracture, as FLC and strain vary with deformation depth for all deformed
shapes. The deformed frustum, as well as the step size and other less
influential criteria, have the greatest percentage contribution and impact on
the findings of the research.
