Comparison of vibration-assisted single-point and two-point incremental forming of sheet metal

Incremental Sheet Forming (ISF) is a versatile and economical forming process that enables the fabrication of complex shapes without tooling. The investigation compares the vibration-assisted Single-Point Incremental Forming (SPIF) and Two-Point Incremental Forming (TPIF) processes for aluminum alloys AA1100 and AA3003. A series of experiments are conducted to assess the performance of the process in terms of maximum wall angle, thickness change, surface finish, forming forces and hardness distribution. The findings show that TPIF offers enhanced dimensional control and thickness distribution control because of the supporting die, but SPIF offers better formability with larger wall angles. The use of vibration assistance leads to a substantial reduction in forming forces and improved surface quality due to reduced friction and interaction between the tool and sheet. But vibration assistance results in a slight loss of formability. Additionally, AA1100 has better ductility and formability than AA3003, while AA3003 has higher forming forces due to its higher strength. This research indicates that vibration-assisted TPIF provides the best compromise in terms of formability, surface finish and thickness distribution. These results offer guidance for the choice of forming processes in advanced sheet metal forming operations, such as in aerospace and automotive manufacturing, where efficiency and accuracy are essential factors.