Experimental and numerical investigation of novel toolpaths on forming quality in DSIF

The toolpath based on the support tool adjustment to the local normal of the master tool has a substantial effect on the final component quality in double-sided incremental forming (DSIF). Two novel toolpaths based on two new support tool positions to the master tool were investigated for their effects on forming quality. These toolpaths were based on adjusting and maintaining the support tool at a specific gap (ϕ = 7.75° and 15.5°) from the local normal of the master tools in the meridional orientation in the direction of the already formed part without pneumatic-assisted support tool. The adjustment of the support tool at ϕ = 7.75° deforms the sheet based on the sheet compression and reverse bending, whereas support tool adjustment at ϕ = 15.5° deforms the sheet based on reverse bending. The two new toolpaths were compared to each other and to a normal DSIF toolpath based on experimental results for geometric precision, surface finish, processing time, and component sheet thickness variation. Simulation results for these toolpaths were also evaluated to support the experimental results and understand the process mechanism. The three main challenges posed by the DSIF process, geometric precision, sheet thickness distribution, and surface roughness, were improved up to 30%, 1.07%, and 21.81%, respectively, using the new toolpaths without compromising the forming time. The combined reverse bending and compression improved the forming quality effectively compared to only reverse bending or compression. These toolpath benefits are the no additional requirements for additional equipment, reducing capital and operational cost.