Analytical prediction of stepped feature generation in multi-pass single point incremental forming

Dongkai Xu, Rajiv Malhotra, N. Venkata Reddy, Jun Chen, Jian Cao*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

36 Scopus citations


Single point incremental forming (SPIF) is a new sheet metal forming process characterized by higher formability, product independent tooling and greater process flexibility. The inability of conventional single pass SPIF to form vertical walls without failure is overcome by forming multiple intermediate shapes before forming the final component, i.e., multi-pass single point incremental forming (MSPIF). A major issue with MSPIF is significant geometric inaccuracy of the formed component, due to the generation of stepped features on the base. This work proposes analytical formulations that are shown to accurately and quantitatively predict the stepped feature formation in MSPIF. Additionally, a relationship is derived among the material constants used in these analytical equations, the yield stress and thickness of the blank material, such that the computational effort required for the calibration of these constants can be minimized. Finally, the physical effects of yield stress and sheet thickness on the rigid body translation are further discussed.

Original languageEnglish (US)
Pages (from-to)487-494
Number of pages8
JournalJournal of Manufacturing Processes
Issue number4
StatePublished - Oct 2012


  • Analytical formulations
  • Geometric accuracy
  • Multi-pass single point incremental forming (MSPIF)

ASJC Scopus subject areas

  • Strategy and Management
  • Management Science and Operations Research
  • Industrial and Manufacturing Engineering


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