Incremental Forming, IF technology is a method for producing complex 3D-dimensional sheet profiles. Compared to conventional forming process, IF has some advantages, such as the punch-die set product deformation is not necessary, lower tools cost, shorter time prototype production, flexibility. The accuracy of the incremental forming products is still lower than those produced by the conventional forming process. One of the main parts of the IF tools-set is the supporting tools. The product profile accuracy limits the simplicity or complexity of the supporting tools. When the product profile does not contain a horizontal surface, the simple supporting tool can be used. If the product profile is more complex, the supporting tools should include more details. The present work introduces the effect of supporting plate radiuses in SPIF, Single Point Incremental Forming process. The supporting plate is used to investigate the effect of springback during the forming process. Aluminum sheet metals (A1025) are used for manufacturing the products. The study objective is to understand the springback behavior, which is affected by supporting tools. The strain distributions of the final deformed product section at each step size have been analyzed and evaluated in detail.

Incremental Forming IF is a suitable technique for producing complex forms. The geometry of product is quite free; on the other hand, there are limitations regarding the sheet thickness and the tools used. The material formability is affected by the product profile requirements, and the straightening of product wall is affected by the tool path. Also, the wall angle is one of most important characteristics that are limited by the sheet profile thickness. The geometry of the product determines the type of supporting tool and its complexity. The horizontal surface can be produced without supporting tool, but will result inclined. Without supporting tool, the sheet tends to bend as an alternative of stretching and the surface becomes wavy. For the present study, Aluminum (A1025) alloy sheets are used to deform a product using a supporting plate (with radius). The supporting plate is used to analyze the effect of springback during the process and for better control over the material flow. The study aims to understand the distribution of strain at the deformed part section for each step size. Also, the primary reasons for the product failure by springback and the final products have been evaluated and analyzed in details.

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.

Incremental Forming process, IF is a technology for producing 3D-dimensional complex sheet profiles. The advantages of the process involve simple set tools, fixture and forming tool, shorter time for producing the pattern, and flexibility. While the main limitation of the process is the springback that represent geometry accuracy, the part profile precision limits the difficulty of forming toolpaths, including the wall angle. This work presents the forming toolpaths effect in the IF process. The supporting space and the product base dimension including wall angle is used to study the springback effect through the incremental forming process. Sheet metals Aluminium-A1025 are used for manufacturing the products. The research goals are to comprehend the springback defect behaviour which is affected by the supporting space-toolpath angle and the supporting space-product base ratios. The strain distributions and the thinning percentage of the final product section have been considered and analyzed in detail.

Incremental Forming IF is a suitable sheet metal forming technique for producing complex forms by local deformation. The forming tool movement follows the designed tool path controlled by the CNC machine programme. The main categories of the process are single point, SP and two points, TP "with enhancement tools". Additionally, the product design determines the enhancement tool type used and its obstacles. The enhancement tools are used for improvement of the product profile quality, while maintaining the simplicity of the process. The material formability is affected by mechanical properties and characteristics of the product profile. The limits are concerning the forming tools used and the blank thickness. On the other hand, due to the difficult environment of these process models, numerical methodologies controlled by Finite Element Method, FEM are currently in extensive use. The research offers the main data and results of a comparing study on the influence of using the enhancement tools in IF through FEM. The study purposes to identify the scientific differences of the IF processes, "with and without enhancement tools" by evaluating the thickness and strains distribution of the deformed blank section. In addition, the analysis and the evaluation of the final product profile have been studied.