Enhancing Formability of Non-Symmetrical Conical Geometries in Single Point Incremental Forming

The single-point incremental forming procedure (SPIF) has the benefit of exceptional formability. Nevertheless, the intricate geometry of the workpiece remains a challenge for achieving desired shape changes using the SPIF process. Thus, this study aims to analyze the outcomes of the asymmetric shaping of cone-shaped workpieces. The characteristics that were examined were the tool’s stepdown and movement direction. An analysis is conducted to examine the alterations in the wall thickness, surface roughness, and microstructural damage of the workpiece following the forming process, using SEM. The findings indicate that the process of step down has a notable influence on the level of surface roughness. The phenomenon of a wider cone angle leads to a reduction in the thickness of the workpiece, which in turn leads to the formation of small internal cracks and eventual failure during the forming process. As the thickness diminishes, the quantity of microcracks augments, rendering the material incapable of withstanding the force exerted during the forming process.