Experimental and Numerical Analysis of Thinning in Incremental Sheet Forming (SPIF) of an Aluminum Alloy (AA3003-H14)

This study examines the thinning behavior of AA3003-H14 aluminum alloy during single point incremental sheet forming (SPIF) through a combination of experimental trials and finite element analysis (FEA) using LS-DYNA. A full factorial experimental design was implemented to assess the effects of wall angle (45°, 55°, 65°) and step size (0.25 mm, 0.50 mm, 0.75 mm) on sheet thinning at various forming depths. Thickness measurements were analyzed using a two-way analysis of variance to determine the significance of process parameters and their interactions. Numerical simulations predicted thickness reduction, effective plastic strain, and von Mises stress distributions, with deviations from experimental results generally remaining below 10%. The findings indicate that wall angle has a dominant influence on thinning, while step size exhibits a moderate effect. The validated FEA model accurately captures localized deformation behavior, offering a predictive tool for optimizing SPIF parameters. This work enhances the understanding of AA3003 thinning mechanisms and supports process improvements for broader industrial adoption of SPIF.