Improvement in formability of copper sheet in single point incremental forming by combined effects of tool stirring action and optimised forming process parameters

Single point incremental forming (SPIF) is an advanced manufacturing process that has gained popularity in the sheet metal industry. The present work focuses an investigation on stirring action of high rpm of tool on the formability of copper sheet. Copper sheets of grade Cu-1100 of thickness 0.5 mm and 1.0 mm were used as testing materials and deformed incrementally with spindle RPM range from 2,000 to 6,000 with different sets of parameters, and the result found was outstanding. In this investigation maximum forming angle obtained was reached to 80° and 84° for 0.5 mm and 1.0 mm thickness of sheet respectively. Highest forming angle obtained was 84° when forming sheet by SPIF with 0.6 mm step depth, 6,000 rpm spindle speed and 250 mm/min forming speed for 1.0 mm thick copper sheet.