Contact statuses distributions of flat forming tool profile effect in incremental forming process by finite element analysis

Single Point Incremental Forming process (SPIF) is a modern forming technique of sheet material. Principles of the process are based on manufacturing by layers-two dimensions layers with step size depth of the tool path. The movement of a hemispherical forming tool is using Computer Numerical Control (CNC) machine to produce the profile of the final product. The description of the process is more complicated by highly nonlinear boundary conditions. The paper presents a study of the effect of the flat forming tool profile through FEA on SPIF that permits the modelling of complex product geometries, material behaviour and boundary conditions. The results showed that the model of simulation can predict the behaviour of contact tool-blank, and the accuracy of product