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<p>This study aims to address the limitation of excessive sheet thinning and failure in single point incremental forming (SPIF) when forming shapes with large wall angles by employing multi-pass incremental forming. Multi-pass single point incremental forming enhances formability for complex geometries with steep wall angles that can’t be achieved in single-pass incremental forming, and are crucial on aerospace and automotive applications. Thickness distributions during multi-pass incremental sheet forming were obtained using geometrical approach and finite element method (FEM) simulation in Abaqus software for the intermediate and final shapes in forming truncated pyramid shapes from 1.0&#xa0;mm thick AA5083 sheet with 60° wall angle in four numbers of passes. Results of FEM simulation could predict thickness distributions better than that of the geometrical method in multi-pass incremental sheet forming with values of 0.374&#xa0;mm for FEM versus 0.347&#xa0;mm by geometrical method in comparison to the experimental value of 0.390&#xa0;mm. Lesser sheet thinning was observed for multi-pass forming with a value of 0.390&#xa0;mm compared to 0.270&#xa0;mm for single-pass forming at a forming wall angle of 60°.</p> Graphical Abstract <p></p>

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Numerical modelling and geometric analysis of sheet thinning in multi-pass incremental sheet forming of AA5083 aluminum alloy

  • 期刊论文

  • 发表日期：

    2025年6月15日

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  • Kameshwar Mahto,
  • Kuntal Maji,
  • Shashi Bhushan Prasad,
  • Gautam Kumar

摘要

This study aims to address the limitation of excessive sheet thinning and failure in single point incremental forming (SPIF) when forming shapes with large wall angles by employing multi-pass incremental forming. Multi-pass single point incremental forming enhances formability for complex geometries with steep wall angles that can’t be achieved in single-pass incremental forming, and are crucial on aerospace and automotive applications. Thickness distributions during multi-pass incremental sheet forming were obtained using geometrical approach and finite element method (FEM) simulation in Abaqus software for the intermediate and final shapes in forming truncated pyramid shapes from 1.0 mm thick AA5083 sheet with 60° wall angle in four numbers of passes. Results of FEM simulation could predict thickness distributions better than that of the geometrical method in multi-pass incremental sheet forming with values of 0.374 mm for FEM versus 0.347 mm by geometrical method in comparison to the experimental value of 0.390 mm. Lesser sheet thinning was observed for multi-pass forming with a value of 0.390 mm compared to 0.270 mm for single-pass forming at a forming wall angle of 60°.

Graphical Abstract