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<p>Single Point Incremental Forming (SPIF) has emerged as a flexible and cost-effective manufacturing process for producing complex geometries in aerospace, automotive, and biomedical applications. SPIF offers significant potential for sustainable manufacturing due to its die-less nature, reduced material waste, and lower energy consumption. In the present study, formability of Lean Duplex Stainless Steel 2101 sheets is systematically investigated by examining the influence of tool size, vertical step depth, and feed rate under ambient conditions. The forming limits were evaluated by developing a Forming Limit Curve (FLC) on a Forming Limit Diagram (FLD) using experimental strain data. The results demonstrate that enhanced formability is achieved with a maximum forming height of 13.58&#xa0;mm and an FLD₀ value of 0.539 under optimal forming conditions of 8&#xa0;mm tool size, 0.2&#xa0;mm vertical step depth, and 1000&#xa0;mm/min feed rate. The results of Analysis of Variance (ANOVA) indicate that the tool size is the primary factor influencing forming height, contributing 38.2%, followed by vertical step depth at 28.5%. The wall thickness distribution exhibited non-uniform variation, ranging from 0.457&#xa0;mm in deformed regions to 0.315&#xa0;mm near the fracture zone, indicating circumferential shearing and localized thinning. Experimental thickness values showed good agreement with theoretical sine law predictions, validating the deformation mechanics. Furthermore, Electron Backscattered Diffraction (EBSD) analysis revealed duplex microstructural evolution characterized by grain elongation and subgrain formation, with the average grain size decreasing from 1.42&#xa0;μm to 1.12&#xa0;μm, indicating strain-induced microstructural refinement governed by phase-specific deformation mechanisms.</p>

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Formability analysis and microstructural evolution of lean DSS 2101 during single point incremental forming

  • 期刊论文

  • 发表日期：

    2026年6月24日

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  • Sudarshan Choudhary,
  • Amit Kumar,
  • Amrut Mulay,
  • Rajesh Khatirkar

摘要

Single Point Incremental Forming (SPIF) has emerged as a flexible and cost-effective manufacturing process for producing complex geometries in aerospace, automotive, and biomedical applications. SPIF offers significant potential for sustainable manufacturing due to its die-less nature, reduced material waste, and lower energy consumption. In the present study, formability of Lean Duplex Stainless Steel 2101 sheets is systematically investigated by examining the influence of tool size, vertical step depth, and feed rate under ambient conditions. The forming limits were evaluated by developing a Forming Limit Curve (FLC) on a Forming Limit Diagram (FLD) using experimental strain data. The results demonstrate that enhanced formability is achieved with a maximum forming height of 13.58 mm and an FLD₀ value of 0.539 under optimal forming conditions of 8 mm tool size, 0.2 mm vertical step depth, and 1000 mm/min feed rate. The results of Analysis of Variance (ANOVA) indicate that the tool size is the primary factor influencing forming height, contributing 38.2%, followed by vertical step depth at 28.5%. The wall thickness distribution exhibited non-uniform variation, ranging from 0.457 mm in deformed regions to 0.315 mm near the fracture zone, indicating circumferential shearing and localized thinning. Experimental thickness values showed good agreement with theoretical sine law predictions, validating the deformation mechanics. Furthermore, Electron Backscattered Diffraction (EBSD) analysis revealed duplex microstructural evolution characterized by grain elongation and subgrain formation, with the average grain size decreasing from 1.42 μm to 1.12 μm, indicating strain-induced microstructural refinement governed by phase-specific deformation mechanisms.