Parametric effects on formability of AA2024-O aluminum alloy sheets in single point incremental forming

Single point incremental forming (SPIF) is a truly die-less forming process which is quite suitable for the batch type and prototype production due to economical tooling cost, shorter lead time and ability to form nonsymmetrical geometries without using expensive dies for manufacturing complex components of sheet metal. This process mainly finds application in the medical sector, aerospace, and automotive industry. Moreover, lack of available information about formability of the process makes it limited for industrial applications. SPIF applicability can be ensured on the industrial scale when appropriate guidelines are highlighted regarding the relation between input parameters and the formability of the process. This paper insights the impact of forming tool shape, tool diameter, wall angle, step size, sheet thickness, and tool rotation on the formability of the AA2024-O aluminum alloy sheet material. Forming depth has been measured by scanning the components using a non-contact 3D scanner. Wall angle and step size have been proved more significant factors which affect the formability greatly.