Examining tool shapes in single point incremental forming

To improve the forming limits and expand the range of potential applications of SPIF, testing was performed on a variety of tool heads, with emphasis on non-standard tool profiles. Two head types have been investigated using a custom 2.5° step curve frustum. The results have been compared to standard hemispherical and flat-bottomed tools. Hemispherical and flat-end profile results correlated with previous work on the subject. Parabolic heads of various shapes were tested, resulting in a decreasing formability and increasing surface quality with increased coefficient. Angle-radius heads of 60°, 70°, and 80° from the vertical were tested, resulting in forming limits approaching that of the 90° flat-end tool, indicating that the reduced stress resulting from increased contact area limits the plastic deformation required for adequate material redistribution.