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<p>Single-point Incremental Forming (SPIF) is an advanced plastic deformation process for complex-shaped shell components. Determining the contact area between the tool and sheet material, as well as establishing a contact model, represents a significant challenge in understanding the deformation mechanisms during the forming process. This paper conducts a theoretical analysis of the principles of single-point incremental forming and explores the mechanical interactions between the tool head and the workpiece. By employing Hertzian contact theory, plate bending deformation theory, and material springback considerations, we develop a theoretical model for the contact area associated with elastic–plastic deformation during tool head pressing on sheet materials, alongside a finite element simulation model. Utilizing this model, we analyze how various process parameters influence the characteristics of the contact area and validate our contact model through experimental methods. This research provides scientific foundations and technical support for predicting forming forces, controlling surface precision in forming processes, and optimizing technological parameters.</p>

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Modeling, simulation, and experimental investigation of tool-part contact deformation in the single-point incremental forming process

  • 期刊论文

  • 发表日期：

    2026年1月3日

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  • ZhangShuai Jing,
  • Jianming Zheng,
  • Zhenyu Wang,
  • Mingshun Yang,
  • Chao Peng,
  • Kunbo Li

摘要

Single-point Incremental Forming (SPIF) is an advanced plastic deformation process for complex-shaped shell components. Determining the contact area between the tool and sheet material, as well as establishing a contact model, represents a significant challenge in understanding the deformation mechanisms during the forming process. This paper conducts a theoretical analysis of the principles of single-point incremental forming and explores the mechanical interactions between the tool head and the workpiece. By employing Hertzian contact theory, plate bending deformation theory, and material springback considerations, we develop a theoretical model for the contact area associated with elastic–plastic deformation during tool head pressing on sheet materials, alongside a finite element simulation model. Utilizing this model, we analyze how various process parameters influence the characteristics of the contact area and validate our contact model through experimental methods. This research provides scientific foundations and technical support for predicting forming forces, controlling surface precision in forming processes, and optimizing technological parameters.