Fundamental Studies on Incremental Forming of Titanium Sheet-Metal

Several aspects of Incremental Forming, an innovative sheet-metal-forming process, were studied. Firstly, an optimal combination of tool and lubricant was explored to form the TA1 (commercial Titanium) sheet-metal parts. Secondly, the effect of the tool diameter on the surface texture of a part was investigated. In addition to this, the influence of the tool diameter on in-plane strain distribution and thickness distribution along a part was also studied. Lastly, experiments were conducted in order to investigate the influence of half-apex angle on thickness distribution along a part to be formed. It has been concluded that the surface coating of sheet-blanks is essential to form the TA1 parts with good surface textures, and the dispersion of MoS₂ powder in grease should be rubbed on the coated surface of the sheet-blank to provide lubrication between the tool tip (tip of a surface-hardened HSS tool) and the sheet-blank surface. Furthermore, the tool diameter has no effect on the texture of a formed surface, the deformation mode, and the in-plane strain distribution on a part. It has also been found that the tool diameter does not influence the thickness distribution along a part; rather this is governed by the Sine of half-apex angle of the part to be formed.