SPIF accuracy improvement by FEM analysis of multi-step tool trajectories with experimental validation

Abstract. This study focuses on the application of Single Point Incremental Forming (SPIF) in modern manufacturing, particularly in batch production where flexibility and cost-efficiency are crucial. SPIF enables forming various shapes with reduced tool-workpiece contact and minimal forming forces. A critical factor affecting product quality is the tool trajectory, which influences material springback and accuracy, leading to issues like geometric deviations and defects such as the pillow effect. To address these challenges, the research proposes Finite Element Method (FEM) simulations to analyze alternative SPIF multi-step tool paths. Focusing on frustum cones made of AA1050-H24 aluminum alloy, the study compares simulation results with experimental data, highlighting a roughing-finishing approach that improves geometric accuracy and reduces defects, making it viable for industrial use.