Towards Single Point Incremental Forming Accuracy: An Approach for the Springback Effect Compensation

The springback effect is a common occurrence in incremental forming, where the formed workpiece elastically deforms and slightly shifts from the desired shape after the tool is released. This phenomenon causes an error between the target and obtained shape, leading to reduced geometric accuracy. It is is a significant challenge in incremental forming and it is a reason why the process has lower accuracy compared to conventional forming methods. This paper presents an off-line springback effect compensation model aiming to generate an optimized toolpath that accounts for the material springback effect. The model is based on an off-line numerical simulation conducted on Abaqus/CAE software. The results demonstrated that the proposed model can effectively reduce the error between the desired and obtained shape by 31.8% for aluminum, 63.2% for copper, and 63.1 % for magnesium.