A review on analytical models for predicting forming force in incremental forming processes.

Incremental sheet forming (ISF) is a forming technique in which a sheet is subjected to gradual deformation to generate the final component using a numerically controlled round/hemispherical tool. Unlike traditional sheet forming, ISF may be done without a die, and the method is known as single-point incremental forming (SPIF). SPIF is superior to conventional sheet forming because it eliminates the need for dies, reduces tooling costs, and is appropriate for producing prototypes and batch manufacturing of automotive components. SPIF has emerged as a feasible method for creating various tailored components for specialized applications in the automobile and biomedical sectors, such as vehicle body parts, dental implants, and knee implants. Nonetheless, ISF is a time-consuming operation. As a result, obtaining great dimensional accuracy in final products is difficult. Some of the identified factors causing inaccuracy in final component geometry include sheet spring back, tool deflections, and rigid body displacements. Accurate prediction of sheet thickness, tool-sheet contact area, and forming forces is required to achieve desired dimensional precision. The current study focuses on analytical models used to predict forming forces in ISF. First, generalized analytical methods that predict forming force based on tensile strength data are explored. Following that, a review of analytical force models taking into account various process characteristics is offered. Force models based on key deformation modes such as shear, bending, and stretching are also summarized [ABSTRACT FROM AUTHOR]