Incremental sheet metal forming: Advances and challenges

J. Cao, Y. Huang, N. V. Reddy, R. Malhotra, Y. Wang

Research output: Contribution to conferencePaperpeer-review

29 Scopus citations


Incremental sheet metal forming has demonstrated its great potential to form complex threedimensional parts without using a matching die. The process locally deforms sheet metal using a moving tool head achieving higher forming limits than those of conventional sheet metal stamping process. The die-less nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet products. Potential application areas include aerospace industries, customized products in biomedical applications and prototyping in the automotive industry. Here, in this paper, following a review of the current stateof- The-art technologies, recent work to further advance the understanding and the potentials of incremental sheet metal forming conducted by this collaborative team will be presented. Specifically, the prediction of forming limits has been conducted using a ductile fracture criterion; an analytical model has been developed to quantitatively understand the effects of tooling and process parameters related to sheet thickness; a CAD-based algorithm for tool-path generation is presented to design tool-path based on the geometry and surface finish requirement in incremental forming; and finally a new double-side incremental forming process is proposed and demonstrated experimentally to form a part with double curvatures on both sides of the initial plane. This new setup can extend the process capability of incremental forming in addition to achieving a better control of surface finish. Finally, discussions on future research directions in incremental forming are presented.

Original languageEnglish (US)
Number of pages16
StatePublished - 2008
Externally publishedYes
Event9th International Conference on Technology of Plasticity, ICTP 2008 - Gyeongju, Korea, Republic of
Duration: Sep 7 2008Sep 11 2008


Other9th International Conference on Technology of Plasticity, ICTP 2008
Country/TerritoryKorea, Republic of

ASJC Scopus subject areas

  • Polymers and Plastics


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