Single-Point Incremental Forming (SPIF) of AA5754 Aluminium Alloy Blanks: Experimental and numerical studies

Abstract

This study presents a Finite Element (FE) simulation model for Single-Point Incremental Forming (SPIF) of a panel part using AA5754 Aluminium Alloy. The precision of model was highly enhanced through experimental data integration by uniaxial tensile tests (UATT) to determine material flow stress and anisotropic properties. The Voce model accurately predicted material flow stress within a 5% error margin, and equations were concluded to convert Lankford coefficients (R-values) into anisotropic stress ratios for Abaqus/Explicit simulation. Experimental validation demonstrated a close agreement in major strain and thickness distribution, with a maximum error below 5.8% across high and low forming speeds.