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<p>Incremental sheet forming (ISF) is a flexible and efficient manufacturing process, particularly suitable for small-batch and customized production. However, its industrial application is often hindered by challenges such as poor surface quality, limited formability at steep wall angles, and uncontrolled thickness variation. To address these limitations, this study aims to systematically investigate the effect of key process parameters—step depth, feed rate, and spindle speed—on critical forming responses, including surface roughness, geometrical accuracy, sheet thinning, microhardness, and forming force. Unlike conventional approaches that rely on extensive heat treatments to enhance formability, this study focuses on varying the process parameters at room temperature to improve forming quality while maintaining structural integrity. Experimental trials, supported by finite element simulations, were conducted on AA6061-T6 alloy sheets to analyze the interplay between process parameters and material behavior. The results demonstrate that step depth and feed rate significantly influence surface roughness, geometrical accuracy, and sheet thinning, whereas spindle speed is the primary factor affecting microhardness. The combination of 0.4 mm step depth, 600 mm/min feed rate, and 1250 rpm spindle speed is optimal for achieving improved surface finish, geometrical accuracy, and overall forming quality. The numerical simulations closely align with experimental observations, validating the predictive accuracy of the proposed approach. The insights gained from this study contribute to improving ISF process reliability and expanding its applicability for complex geometries in industrial settings.</p> Graphical Abstract <p></p>

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Experimental and Numerical Investigation of Industrial-Grade AA6061 T6 for Improved Forming Qualities in Incremental Forming

  • 期刊论文

  • 发表日期：

    2025年9月2日

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  • Viren Mevada,
  • Rakesh Bose,
  • Harit Raval

摘要

Incremental sheet forming (ISF) is a flexible and efficient manufacturing process, particularly suitable for small-batch and customized production. However, its industrial application is often hindered by challenges such as poor surface quality, limited formability at steep wall angles, and uncontrolled thickness variation. To address these limitations, this study aims to systematically investigate the effect of key process parameters—step depth, feed rate, and spindle speed—on critical forming responses, including surface roughness, geometrical accuracy, sheet thinning, microhardness, and forming force. Unlike conventional approaches that rely on extensive heat treatments to enhance formability, this study focuses on varying the process parameters at room temperature to improve forming quality while maintaining structural integrity. Experimental trials, supported by finite element simulations, were conducted on AA6061-T6 alloy sheets to analyze the interplay between process parameters and material behavior. The results demonstrate that step depth and feed rate significantly influence surface roughness, geometrical accuracy, and sheet thinning, whereas spindle speed is the primary factor affecting microhardness. The combination of 0.4 mm step depth, 600 mm/min feed rate, and 1250 rpm spindle speed is optimal for achieving improved surface finish, geometrical accuracy, and overall forming quality. The numerical simulations closely align with experimental observations, validating the predictive accuracy of the proposed approach. The insights gained from this study contribute to improving ISF process reliability and expanding its applicability for complex geometries in industrial settings.

Graphical Abstract