Journal of Materials Processing Technology 177 (2006) 409412

Optimization of tool path in two points incremental forming

A. Attanasio a, , E. Ceretti a , C. Giardini b
a

Universit`a di Brescia, Dipartimento di Ingegneria Meccanica, via Branze, 38, 25123 Brescia, Italy
Universit`a di Bergamo, Dipartimento di Progettazione e Tecnologie, viale Marconi, 5, 24044 Dalmine (BG), Italy

Abstract
Asymmetric sheet incremental forming is a relatively recent sheet metal forming process introduced to reduce the costs of sheet metal forming
when low volume batches or customized parts or prototypes have to be manufactured. In recent years, this forming process saw a very rapid
development, thanks to the international researches conducted by many international research centers. The present work deals with the optimization
of the tool path in two point sheet incremental forming, with a full die in a particular asymmetric sheet incremental forming configuration. The
aim of the study was the experimental evaluation of the tool path, which is able to reproduce an automotive component with the best dimensional
accuracy, the best surface quality and the lowest sheet thinning.
2006 Elsevier B.V. All rights reserved.
Keywords: Two points incremental forming; Tool path optimization; CAD-CAM design

1. Introduction
In recent years, in sheet metal forming field, new types of
forming processes were introduced in order to reduce the manufacturing costs and the time to market when pre series or
prototypes need to be produced.
In particular, a new process that incrementally deforms the
sheets, named asymmetric sheet incremental forming (ASIF) or
dieless forming as patented in 1967 by Leszak [1], has recently
been extensively investigated. The ASIF process is generally
based on the idea of equipping a general purpose CNC machine
with a special tool, that deforms the sheet following a path with
or without the support of a die. As reported in [2,3] several ASIF
configurations have been designed and studied. So, depending
on the number of contact points between sheet, tool and die, it
is possible to distinguish between Two points incremental forming (TPIF) with partial or full die, and single point incremental
forming (SPIF). Since in SPIF the sheet is not supported by any
die, the resultant strain and stress fields into the sheet thickness
are different than in TPIF [3], allowing best drawing ratio [4],
but with lowest dimensional and geometrical accuracy of the
final part.
The research here presented reports an experimental optimization of the tool path in TPIF used to manufacture an automo-

Corresponding author. Tel.: +39 030 371 5584; fax: +39 030 370 2448.
E-mail address: aldo.attanasio@ing.unibs.it (A. Attanasio).

0924-0136/$ see front matter 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2006.04.047

tive component (door handle of a commercial car). In particular,

the applied technique uses a full die and a shaped blankholder.
Two different tool path types have been investigated and their
effect on surface quality, dimensional accuracy and thinning was
analyzed. The first tool path type was realized with a series of
incremental contours at constant step depth. The second tool
path was made by a set of incremental contours with a variable step depth to minimize the value of the so called scallop
height. The investigated paths were generated using commercial 3D CAD-CAM software. As far as the results are concerned,
the influence of the tool path was analyzed evaluating the surface
quality, the dimensional accuracy and the final sheet thickness
for each path type. A high product quality was obtained, showing that it is possible to get safe parts respecting the shape and
geometry tolerances by using this innovative sheet metal forming technique.
2. Process and tool paths
Fig. 1 shows the car bodywork feature studied. TPIF with full
die was used to manufacture this automotive part. The sheet is
deformed on both external and internal surfaces by the pressure
applied to the sheet from the tool and the die. Using this sheet
incremental forming technique it is possible to obtain a good
dimensional accuracy of the part geometry (reduced springback), as reported in [5,6].
The experimental tests were performed on a milling machine,
equipped with die and tool, which allow the sheet metal forming.

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Table 1
Values of the investigated parameters

Fig. 1. Bodywork car feature.

Metal sheets made of Fe P04 steel with a thickness of 0.7 mm and

250 mm 150 mm dimensions were used. Two different blank
holder shapes were used: a flat one (traditional) and a shaped
one, which fits the part geometry (in this last case also the sheet
needs to be pre-formed to guarantee the best clamping between
sheet and die).
The die and the shaped blankholder were made of epoxy
resin, this gave the possibility of reducing the die material and
machining costs since the forces acting on the die are very low.
The tool used in all the tests had an hemispherical head with a
diameter of 20 mm. Grease was applied to lubricate the working
surfaces so improving the surface finishing.
As far as the tool path is concerned, particular attention was
focused in its design. The main objective was to find the tool
path giving the best results in terms of surface quality, geometry accuracy and sheet thinning. A commercial 3D CAD-CAM
software was used for the realization of the two tool path types:
1. Type 1: pocketing with constant step depth (
Z). It is a step
down path from the top to the bottom of the pocket, in which
the tool follows a series of consecutive contours with fixed
step depth (Fig. 2). Two disadvantages are associated with
this type of tool path: the sheet is marked at the transition
point between consecutive layers; and the quality of flat or
near to flat surfaces is poor when high
Z values (more than
0.5 mm) are used.

Parameter

Values

Step depth (
Z) (mm)

Scallop (Sc) (mm)
Tool type

0.2; 0.5; 1.0

No scallop; 0.1; 0.02

Z constant; Sc constant

2. Type 2: pocketing with constant scallop height (Sc). It is a

step down path from the top to the bottom of the pocket, in
which the tool follows a series of consecutive contours with
variable step depth (
Zmax must be furnished) in order to
keep constant the value of the scallop height (Fig. 2). This
kind of path reduces the disadvantages of the first type. In
particular, the flat surfaces show a better quality.
Step depth, scallop height and type of tool path influences
were studied during the experimental tests, changing their values as reported in Table 1. All the other parameters were kept
constant, in particular the feed rate was set equal to 1500 mm/min
and the spindle speed equal to 100 rpm.
3. Results
As already mentioned, the experimental tests were conducted
on flat and pre-formed sheets. Only the results referred to preformed sheets are reported in the following since with a flat blank
holder it was impossible to correctly reproduce the shape of the
pocket because the sheet material, without being constrained on
the die geometry, wrinkled.
3.1. Surface quality
To evaluate the surface quality of the produced parts as the
tool path changes, the sheet profile was measured using a CMM.
In particular, the bottom of the pocket was analyzed, because
the scallop parameter mainly influences the quality of this area.
Fig. 3 reports the best and worst measured bottom profiles and
the pictures of the obtained parts. It is evident that the surface
quality can be improved decreasing the values of both step depth
(
Z) and scallop height (Sc), obviously this causes an increase in

Fig. 2. The two tool path types and the influence of scallop height parameter.

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411

Table 2
Maximum percentage sheet thinning of pre-formed sheets

Fig. 3. Comparison between the best (
Zmax = 0.2 mm, Sc = 0.02 mm) and the
worst (
Zmax = 1 mm, no scallop) bottom profiles.

Test

Thinning (%)

Z 0.2 mm, No Sc

Z 0.5 mm, No Sc

Z 1.0 mm, No Sc

Zmax 0.2 mm, Sc 0.1 mm

Zmax 0.5 mm, Sc 0.1 mm

Zmax 1.0 mm,Sc 0.1 mm

Zmax 0.2 mm, Sc 0.02 mm

Zmax 0.5 mm, Sc 0.02 mm

Zmax 1.0 mm, Sc 0.02 mm

27.14
26.71
26.86
24.29
27.14
27.00
26.14
28.43
25.71

geometry is not correctly reproduced (the pocket bottom is far

from the ideal profile).
3.3. Sheet thickness

the manufacturing time. The big waves characterizing the worst

profile are caused by the tool position.
3.2. Dimensional accuracy
Regarding the dimensional accuracy, the external profile of
the pocket (i.e. the side in contact with the die) was measured
along two orthogonal axis (Fig. 5) by using a CMM. Fig. 4 shows
the influence of the scallop height (Sc) (Fig. 4a) and of the step
depth (
Z) (Fig. 4b) on the dimensional accuracy of the final
part. The best result was obtained using the tool path type 2 with
a maximum step depth equal to 0.2 mm and scallop height equal
to 0.02 mm, while the worst refers to tool path type 1 with step
depth equal to 1.0 mm.
Observing the curves of Fig. 4, it is evident that when using
tool paths with high step depth or high scallop values the pocket

A thickness analysis was carried out for each performed test

by using a micrometer. The thickness was measured with a step
of 2 mm along two orthogonal axis as shown in Fig. 5. Table 2
reports the maximum thinning of the sheet for each tool path. No
relevant differences can be observed between the several tests.
3.4. Comparison between pre-formed and at sheets
Fig. 5 shows the measured thickness comparison between
pre-formed and flat sheets when using the best tool path in terms
of surface quality and geometrical accuracy (
Zmax 0.2 mm and
Sc. 0.02 mm). As already mentioned, the worst results were
obtained when using flat sheets. In particular, the bottom of the
pocket (X = 0, Y = 0) and the area highlighted with a circle in
Fig. 5 showed the maximum difference between the two curves
due to the sheet wrinkling.

Fig. 4. Scallop height (a) and step depth (b) influence on dimensional accuracy.

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Fig. 5. Thickness comparison between preformed and flat sheet (tool path type 2 with
Zmax = 0.2 mm and Sc = 0.02 mm).

4. Conclusions
This research aimed at improving the knowledge of two point
incremental forming with full die. In particular, the importance
of the tool path design in sheet incremental forming was investigated. The experimental tests demonstrated that to reach good
results in terms of surface quality, geometric accuracy and thickness of the final part, it is important to use a tool path with a
variable step depth (depending on the part geometry) and, in
particular, to correctly set the value of: the maximum step depth
(
Zmax ) and the scallop height (Sc). The best choice, as shown,
is to set low values of both these parameters (
Zmax 0.2 mm and
Sc. 0.02 mm) even if the working time increases. The working
procedure based on the maximum scallop height was taken from
the field of metal cutting operations. In fact, to get the best final
roughness in dies and moulds production it is a normal practice
to use tool paths optimized setting the maximum allowed scallop
height.
Finally, the TPIF process can be successfully used either to
manufacture or to finish prototypes using the same material of

the series production parts and guaranteeing the geometrical and

esthetic requirements without the need of too expensive dies or
equipments.
References
[1] E. Leszak, Patent US 3342051A1, published 1967-09-19, Apparatus and
process for incremental dieless forming.
[2] J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, J. Allwood, Asymmetric single point incremental forming of sheet metal, Ann. CIRP 54
(2) (2005).
[3] J. Jeswiet, Asymmetric incremental sheet forming, in: Proceeding of the
11th International Conference on Sheet Metal, Erlangen-Nuremberg, Germany, 2005, pp. 3558.
[4] L. Filice, L. Fratini, F. Micari, Analysis of material formability in incremental forming, Ann. CIRP 51 (1) (2002).
[5] R. Shankar, S. Jadhav, R. Goebel, W. Homberg, M. Kleiner, Incremental sheet metal forming of preformed sheets, in: Proceeding of the 8th
International Conference on Technology of Plasticity, Verona, Italy, 2005.
[6] G. Hirt, M. Bambach, S. Junk, I. Chouvalova, FEM modeling and optimization of geometric accuracy in incremental CNC sheet forming, in:
International Conference on Accuracy in Forming Technology, 10th Saxon
Conference on Forming Technology, SFU, 2003.