Incremental Sheet Forming (ISF) is a flexible and innovative rapid prototyping technique for the fabrication of limited sheet metal components. In the present investigation, the dependency of formability and thickness reduction of ISF parts on tool diameter, incremental step depth along with the preheating of sheet material has been determined. After preheating, initial grain size of the sheet material is selected as a parameter under study. Incremental Sheet Forming process has been studied using Taguchi design of experiments along with Response surface methodology (RSM). ANOVA, 3D surface graphs, S/N ratio and main effect plots have been analyzed. Results indicated that the initial grain size is the most significant parameter as far as forming load and thickness reduction is concerned in ISF. Preheating of the sheet material reduces forming load and favors homogenous thickness distribution. Response surface is optimized and a model developed can be used to predict forming load and thickness reduction within the limits of factors being studied.

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