ANALYSIS OF THE CURRENT STATE OF RESEARCH ON THE PROCESS OF INCREMENTAL SHEET FORMING

Abstract

The paper presents a generalized analysis of the current state of research on the process of incremental sheet forming, which is considered a promising method for manufacturing thin-walled parts under conditions of single and small-batch production. The relevance of this study is determined by the need to increase the flexibility of mechanical engineering production, reduce the cost of manufacturing specialized stamping tooling, and ensure high product quality when producing small batches of parts with complex geometries.

The article examines the main types of incremental sheet forming and analyzes their structural and technological features, advantages, and limitations of application. Considerable attention is devoted to the study of the influence of the main technological parameters of the process, including the tool path trajectory, feed rate, tool rotational speed, forming step size, radius of the tool contact surface, and lubrication conditions. The results of experimental and numerical studies aimed at evaluating their influence on the stress–strain state of the material, geometric accuracy, surface roughness, and force characteristics of the forming process are summarized.

Special attention is paid to the influence of technological equipment characteristics on the stability of the forming process and the positioning accuracy of the working tool. The features of the formation of a complex three-dimensional stress–strain state in the contact zone between the tool and the sheet blank are highlighted, and the mechanisms of damage accumulation in the material during sequential local loading are considered.

Based on the analysis performed, the main directions for further research are identified, including the improvement of methods for predicting limiting deformations and material fracture, consideration of technological heredity in the forming process, and the development of recommendations for optimizing the technological parameters of incremental sheet forming in order to increase the accuracy, reliability, and efficiency of manufacturing parts with complex shapes.