Maytham Saad Ali Hnoosh

Incremental sheet metal forming (ISMF) is a highly flexible and versatile process to produce complex sheet metal parts and rapid prototypes. Its adaptability to (CNC) systems is excellent through direct control of CAD data, minimizing the use of heavy machines, high cost tooling and pressing equipment. A sheet of metal is formed by using a simple forming tool driven by a CNC milling machine localizing pressing force to plastically deform the part during progression. In this work, like pyramid shape manufactured by(SPIF) process without using any dedicated dies. The aim is to measure the influence of forming the angle on the dimensional accuracy (depth error) of the formed part. Different angles (30°, 45°, and 60°) used to create pyramid shape and all the experiments carried out on an aluminum alloy sheet with0.5 mm thickness by using a three-axis conventional milling machine, this machine also used to measure dimensions accuracy of the part. Results show that the forming angle (30°) is gives the higher geometrical accuracy when forming the pyramid shape.

Incremental sheet metal forming is adaptable rapid manufacturing in sheet forming process that lead to cost and time effective and good quality products, more flexible and less set up cost to any complexity parts, so that it is highly versatile nowadays. Therefore, incremental sheet metal forming technology solving many problems found in conventional sheet forming. More than researchers continue in studying improvement (ISMF) process. In this work, simple and complex shapes manufacture by Single Point Incremental Forming process (SPIF) without using a dedicated die depending on helical tool path was generated by UnigraphicsNX10 (UGS-NX10) programing system. The aim of the presented work is to investigate the feasibility of the incremental forming process for different geometry shapes by using computer numerical control (CNC) depending on zero spindle speed using 1050 aluminum sheet material. The results from this work gives good indication about the complexity of using different shapes in (ISMF). Therefore, improvement of this process by using different shapes as a design tool for incremental sheet forming very important things.