Single-point incremental forming of 6061-T6 using electrically assisted forming methods

In this article, large direct current is applied through the tool to improve formability while forming 6061-T6 Al using single-point incremental forming. Special attention is paid to the direct effect of current density, as opposed to bulk resistive heating, to determine whether the electroplastic effect is significant in raising the formability without requiring temperature rise. Tests are performed to determine the maximum wall angle that can be formed for a variety of current and tool settings. The area of contact between the tool and sheet is modeled, and a control system is proposed and tested to vary the current to maintain a constant current density during tests. The phenomenon of current threshold density is observed at a current density range agreeing with previous studies forming the same material in different loading cases. A significant formability increase is observed at a range of current density values that agree with previously published work with this material in different loading cases. Surface roughness and spalling are also shown to be directly affected by current.