FLD and Fractography Analysis of Multiple Sheet Single Point Incremental Forming

The single point incremental forming (SPIF) process is gaining importance in academic, research and industrial sectors due to its inherent advantages over conventional sheet metal forming processes, viz., high formability, non-dependence on dies and process simplicity. Hence, the process is highly recommended for rapid prototyping applications, but the slowness of the process is a major disadvantage that prevents industries from implementing it on a wider scale. The possibility of using low thickness multiple sheets in a SPIF process is explored in this paper, and the results show the mechanism of sheet failure, new surface generation and the extent of achievable forming limits from the top sheet to the bottom sheet while forming multiple sheets together.