Process window enhancement for single point incremental forming through multi-step toolpaths

Single point incremental forming (SPIF) suffers from process window limitations which are strongly determined by the maximum achievable forming angle. Forming consecutive, intermediate shapes can contribute to a significantly enlarged process window by allowing steeper maximum wall angles for a range of part geometries. In this paper an experimentally explored multi-step toolpath strategy is reported and the resulting part geometries compared to simulation output. Sheet thicknesses and strains achieved with these multi-step toolpaths were verified and contribute to better understanding of the material relocation mechanism underlying the enlarged process window.