Experimentation and FE simulation of single point incremental forming Shoib Khan, Sharad K. Pradhan ⇑ Department of Mechanical Engineering, National Institute of Technical Teachers’ Training and Research, Bhopal 462002, India article info Article history: Received 6 August 2019 Accepted 17 September 2019 Available online xxxx Keywords: Incremental forming AA 8011 Process parameters Experimentation Optimization Finite element simulation abstract One of the emerging flexible forming technologies in the sheet metal engineering is the incremental sheet forming, it uses universal tooling that is mostly part independent. Hence this process provide higher flex- ibility reducing the product development greatly and making it useful for low volume production. Single Point Incremental forming is drawing attention of the researchers & scientist all over the world because of the attractive characteristics. Like: improved formability, elimination of die & conventional press and ease of operation on general purpose Vertical Machining Centre. As this way of creating sheet metal formed products is in development stage, the factors affecting this needs comprehensive investigations. In this paper experimental and numerical investigation of formability of Aluminium 8011 alloy are pre- sented and compared by preparing a conical frustum shape using SPIF process. The complete process is simulated using CATIA manufacturing simulation model to generate the path of Hemispherical end tool tip. Numeric Control (NC) part program is generated with the help of this simulated path to form the sheet into conical frustum shape on CNC mill machine. Four process parameters viz. vertical step depth, feed rate, spindle speed and angle of cone are chosen for the experimental investigations keeping height of the cone and material sheet thickness constant. Temperature, thickness reduction, strain and machin- ing time are selected as a response variable. Optimizations are performed using TAGUCHI and ANOVA while the numerical study of the process is performed through ANSYS workbench software to predict stress, strain, temperature and thickness Results of experiments and numerical study are in close accord. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods. 1. Introduction Analyst, everywhere throughout the world have contributed in the improvement of the ISF process. Kumar et al. [1] investigated effects of various information factors on forming forces in SPIF pro- cess. It was reasoned that, for activity supportability and equip- ment security, it winds up basic to improve forming forces for a given arrangement of components to frame a specific shape. Effects viscosity of lubricants and took have additionally been researched. Sharma et al. [2] investigated formability of aluminium alloy by setting up a pyramid shape utilizing spif and part program is pre- pared utilizing a C++ language. Three significant indicators factors picked for the examination are: vertical step depth, program methodology and inclination of pyramid. Simulation is likewise done utilizing LS-DYNA software. Bhoyar et al. [3] perform spif forming process by utilizing traditional CNC milling machine to produce various biocompatible metallic and non-metallic cus- tomized implantable devices. Kumar et al. [4] developed a research facility setup of SPIF machine a movement card to control the 3 servo motors for controlling individual 3-axis and spindle develop- ment at IIT (BHU), Varanasi. The strain dissemination on the sheet over the length of deformation has been figured. Simple simulation had done, and surface quality was measured. Tomas et al. [5] per- formed investigation of the free style surface milling depended on the discontinuity of free structure surfaces in device making point- ing out that it is volume based fracture of free structure surfaces which permits to relate CAD plan of tooling parts their displaying and delivering in picked scale just as testing distinctive milling sys- tems methodologies. Srinivasan et al. [6] examined SPIF on Stain- less steel sheet grade 316(AISI), 0.8 mm thick utilizing frustums of pyramid size 100  100  55 mm to decide the ideal parameters Microstructure study was also studied to find the microstructural behavior of the grains for the process on the material. Bagudancha et al. [7] studied the forces during SPIF of different geometry by varying in its slant and bending conditions. Belchior et al. [8] Uti- lized coupling philosophy to address the tool-path deviations https://doi.org/10.1016/j.matpr.2019.09.123 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods. ⇑ Corresponding author. E-mail address: spradhan@nitttrbpl.ac.in (S.K. Pradhan). Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr Please cite this article as: S. Khan and S. K. Pradhan, Experimentation and FE simulation of single point incremental forming, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.09.123