Incremental Sheet Metal Forming: A Die-Less Rapid Prototyping Process for Sheetmetal

This paper presents an account of some investigations into a new die-less rapid prototyping process for sheetmetal forming, namely Incremental Sheetmetal Forming (ISF). The process involves the use of a single smooth tool to carry out local sheet metal deformation progressively on a CNC milling machine. The controlled movement of the tool enables a 3-Dimensional profile to be made. The process can offer rapid prototyping advantages for sheetmetal parts to be made directly from a 3D CAD model to the finished product without the traditional intermediate stage of tool design and manufacture. The paper describes an investigation into the capabilities of the ISF process by using experimental data to develop a tool-path generation methodology for generic materials and shapes. This is achieved by looking at a number of process variables, such as tool rotational speed and tool feed rates, on surface finish, as well as dimensional accuracy. The ISF process can offer the advantages of short lead times, high flexibility and low cost for volume applications.