Single point and asymmetric incremental forming

This paper presents an update on single point incremental forming (SPIF) of sheet metal since 2005. It includes a description of the process with new information on the maximum forming angle, ϕ_max, for 5052-H32. An in-depth example of the successful design and production of parts is given for industry. This includes discussion on production times and surface roughness with details that will help designers. A general design guide for users of SPIF is provided. It is based upon experience gained in the last decade. In general, materials show a trend of decreasing formability with increasing initial thickness. It is shown that for thicker sheet metal, it is recommended using large spherical tools (12.7 mm or larger), or a large flat-ended tool. The flat-ended tool provides the best combination of good formability and very low surface roughness. For aluminum, galvanized steel and stainless steel, it is recommended using a flat-ended tool. Advances in multi-pass techniques and information on successful and useful numerical models which predict forming behaviour are included. Finally, there is a discussion on future work needed in SPIF.