Numerical-experimental single point incremental forming of thin circular plate

Single Point Incremental Forming (SPIF) represents a transformative shift in sheet metal manufacturing, offering unparalleled flexibility, reduced tooling costs, and adaptability for low-volume and customized production. This study presents a hybrid numerical-experimental investigation of SPIF applied to thin circular galvanized plates, integrating finite element simulations via FormingSuite software with experimental validation. A key innovation of this work lies in its detailed analysis of coupled deformation modes, tensile-tensile and tensile-compressive, governing failure and thinning mechanisms under high forming angles, particularly around 90°, which are typically fracture-prone. The research introduces a novel use of the Fracture Forming Line (FFL) over traditional Forming Limit Curves (FLCs) to better predict failure in SPIF. Results reveal improved strain capacity and process stability, supported by deformation mapping, safe zone identification, and stress-strain simulations. This comprehensive approach not only enhances the predictive capabilities of SPIF modeling but also supports smarter and more sustainable manufacturing processes.