ESAFORM benchmark 2024 : study on the geometric accuracy of a complex shape with single point incremental forming

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Vanhulst, Marthe and Lee, Youngrok and Steinfels, Dennis and Bremen, Thomas and Perzyński, Konrad and Vanhove, Hans and Ambrogio, Giuseppina and Breaz, Radu-Eugen and Buffa, Gianluca and Conte, Romina and De Napoli, Liugi and Fratini, Livan and Fu, Xiao Da Terrence and Gagliardi, Francesco and Gralha, Margarida and Kang, Putong and Kuczek, Łukasz and Kumar, A. Senthil and Kunke, Andreas and Leonhardt, André and Li, Yanle and Li, Zhuoer and Licari, Roberto and Long, Hui and Low, Darren Wei Wen and Racz, Sever-Gabriel and Scholz, Peter and Silva, M. Beatriz and Song, Shaoqi and Weise, Dieter and Żaba, Krzysztof and Zhu, Hui and Bailly, David and Banu, Mihaela and Madej, Lukasz and Duflou, Joost R. (2025) ESAFORM benchmark 2024 : study on the geometric accuracy of a complex shape with single point incremental forming. International Journal of Material Forming, 18 (3). 72. ISSN 1960-6214 (https://doi.org/10.1007/s12289-025-01928-1)

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Abstract

The benchmark 2024 project on Incremental Sheet Forming (ISF), involving 15 research institutes in 13 experimental contributions, provided a unique opportunity to compare experimental outputs from various setups and forming strategies in ISF. This collaboration led to the development of uniform data exchange formats, measurement guidelines, and standardized nomenclature, fostering efficient future collaborations. The project addressed challenges in geometric accuracy when forming a relatively large part (400 × 400 mm) using Single Point Incremental Forming (SPIF) and focused on multiple common pitfalls in ISF, in particular the tent effect and pillow effect. Additionally, some experiments have been conducted using Two Point and Double Sided Incremental Forming (TPIF and DSIF). By combining the knowledge and experience of all participating institutes, this project aimed to provide insights into effective parameter choice and toolpath strategies, and shows the importance of multi-stage processes to increase the geometric accuracy. Despite the theoretical simplicity of SPIF setups, such multi-stage toolpath strategies directed toward improved geometric accuracy also add some new challenges. The study highlighted the need for multi-stage strategies that focus on local effects, as well as geometric compensation techniques to enhance ISF's industrial applicability. Alternative process variants like TPIF and DSIF, showed promising results, but they also had limitations and presented challenges, emphasizing the importance of predictive simulation tools to further increase geometric accuracy. The scalability of ISF experiments remains a significant challenge, necessitating further research into scale laws for process optimization.

ORCID iDs

Vanhulst, Marthe, Lee, Youngrok, Steinfels, Dennis, Bremen, Thomas, Perzyński, Konrad, Vanhove, Hans, Ambrogio, Giuseppina, Breaz, Radu-Eugen, Buffa, Gianluca, Conte, Romina, De Napoli, Liugi, Fratini, Livan, Fu, Xiao Da Terrence, Gagliardi, Francesco, Gralha, Margarida, Kang, Putong, Kuczek, Łukasz, Kumar, A. Senthil, Kunke, Andreas, Leonhardt, André, Li, Yanle, Li, Zhuoer, Licari, Roberto, Long, Hui, Low, Darren Wei Wen, Racz, Sever-Gabriel, Scholz, Peter, Silva, M. Beatriz, Song, Shaoqi, Weise, Dieter, Żaba, Krzysztof, Zhu, Hui ORCID logoORCID: https://orcid.org/0000-0003-2310-9116, Bailly, David, Banu, Mihaela, Madej, Lukasz and Duflou, Joost R.;
CORE (COnnecting REpositories)