Finite element modelling of deformation behaviour in incremental sheet forming of aluminium alloy

In this paper, the finite element method (FEM) is used to study the incremental sheet forming process of pyramidal shape. The material used is aluminium alloy 5052. The tool, a hemispherical ball-head with a diameter (d = 4 mm) made of HSS tool steel, is used to press down on the sheet metal causing locally plastic deformation. The comparison between spiral tool path, spiral-step tool path and z-level tool path is carried out. Moreover, the final thickness distribution is investigated. The results indicate that the minimal thickness can be found on the corner of wall angle in SPIF process. Under the same step over, spiral-step tool path can obtain the deepest depth for pyramidal shape. The maximum formability for successful forming of the pyramidal shape with depth 60mm is wall angles 65 degrees.