The aim of this paper is to develop a systematic method to analyze the effects of Forming parameters on the quality of part formability and determine the optimal combination of the Forming parameters for the sheet hydroForming process. In this paper, the effects of four important process parameters namely fluid pressure, friction coefficient at blank/punch interface, gap between die rim block and blank holder and die entrance radius in the process of hydrodynamic deep drawing assisted by radial pressure (HDDRP) were determined. A Finite Element (FE) model was developed for simulating the HDDRP process. After validation of the developed FE model by experimental results, by combining FE simulation with Taguchi method and using the analysis of variance test, the effect of mentioned parameters on the formability of the hydroformed cups was investigated. The applied materials were pure copper and St14 steel sheets. The results of analysis indicated that for both cases of maximum thinning ratio at the constant value of cup draw depth and maximum accessible draw depth, fluid pressure has the greatest influence on the formability of part in sheet hydroForming process. Moreover, using rough punch, having smaller gap between die rim block and blank holder or increasing the die entrance radius, the formability of sheet will improve.

Nowadays, by technology progression (CAD), controlling tools movement in Incremental Forming process, caused improvement of Forming function mechanism-manufacturing symmetrical and asymmetrical pieces, as by determination of an ideal direction pattern and the way of contacting tools with pieces, Caused improvement of Forming behavior in sheet metals and geometry firming of complicated forms, was used in airspace and auto-making industries. In present research two-point incremental Forming of sheet metal was studied experimentally by investigating priority of tool movement in negative and positive limit of geometrical profile in central cavity die. Moving pattern of tools rotationally and spindle axis constant of system (Z) around die geometrical profile, was investigated for positive and negative Forming. Used sheet metal in this research is 1050 Aluminum with 15mm thickness. The results of die geometrical profile showed that critical area with maximum thinning led to tearing of all samples of sheet metals in negative Forming limit while moving pattern of rotator caused decrease of tearing rate and thinning relative to constant tools in sheet metal. Maximum rate of deep, formed in negative critical area of die geometrical profile, occurrence time of tearing in sheet metal Z=-25. 2mm in rotational case of tools with first negative and second positive Forming pattern, is the most ideal two-point Forming case in central cavity pieces

Vacuum Forming is one of the Forming processes of plastic sheets. This process is particularly popular due to its simplicity and high production speed and the removal of one of the dies. The main idea of this research is the feasibility of generalizing the vacuum Forming process for Forming metal sheets. For this purpose, the available design alternatives were considered. In the experimental tests, the shape of the die and, as a result, the workpiece, was considered as a sector of sphere. By comparing the stress-strain diagram of Polyethylene terephthalate, which is widely used in vacuum Forming, with the diagram of pure copper sheet, the temperature of 600 ºC was chosen for this purpose. A high-frequency induction furnace is used for heating the workpiece. Also, by using two pneumatic jacks, auxiliary forces have been applied to form the sheet. On the surface of the blank holders, using a drawing bead in the form of a ridge with a circular cross-section, has been tried to eliminate the wrinkling caused by Forming. Among the different thicknesses of the studied sheet, it is possible to form copper sheets in the range of 0.4 to 0.7mm up to a total drawing ratio of 58% still, but with the current configuration, sheets with less thickness should be studied.

Incremental sheet Forming is one of the novel processes, which is used for rapid prototyping and manufacturing of parts with complex geometries. Forming limit of sheet metal in this process is high compared to other conventional Forming processes. In this paper, warm singlepoint incremental Forming process through uniform heating to sheet along with tool heating is studied experimentally and numerically. Formability of sheet is investigated in various process condition based on the straight groove test in experimental approach and numerical simulation, using finite element method. Tool heating along with uniform heating to sheet makes tool and sheet isothermal, reduces the heat loss in deformation zone, and improves the deformation process. So, attainment of high Forming limit is made possible. Comparison of Forming limit diagrams obtained from experimental and numerical approaches shows a good agreement between the results. Effects of temperature and feed rate on the Forming limit of aluminum 1050 sheet are investigated. Results show that increasing the temperature improves the formability of sheet significantly; but, the temperature is more influential on Forming limit in low feed rates. Increasing the feed rate reduces the Forming limit slightly; this effect is more evident in higher temperatures.

Regarding to the uprising need for production of new components with high efficiency, application of methods that could facilitate the prototyping and minimize the financial and time costs are of high importance. Single Point Incremental Forming, which is a process with no need for die manufacturing, was successful in minimizing the costs and the prototyping period required for design validations. Accordingly, studying this process from different perspectives and obtaining an accurate method for determination of failure in this procedure is important. Some of the benefits of this process are an increase in formability, high flexibility in production of complex shapes and reduction of Forming forces. In all available processes that are used for Forming of metallic sheets there is a certain limit for formality beyond which typical failures including wrinkle, necking or rupture will occur. Today different experimental and numerical methods are developed for determination of Forming limit. In this study in order to obtain the Forming limits and to anticipate the failure in Single-Point-Incremental-Forming process, generalized Forming limit diagrams are utilized. Initially the Single Point Incremental Forming process is simulated using ABAQUS Software and then resulting strain path of critical elements of the part are compared against the Forming limits obtained by generalized Forming limit diagrams to study the existence of failure in both simulations and experimental tests.

In recent years, in order to reducing die design and manufacturing costs, Multi point Forming technique has gained an increasing interest because of its high flexibility. In this process, the conventional fixed shape solid die sets are replaced with a pair of opposite matrices of controllable elements. In this paper, the fundamental principles of multi-point Forming was described and the possibility of Forming the one sheet metal part by this technique was investigated experimentally and analyzed using finite element simulation. Wrinkles and dimples are the most typical defects in multi-point Forming of sheet metal. By the proper selection of process parameters the sound cup with good surface quality and uniform thickness distribution can be formed. The results obtained demonstrated that multi-point Forming technology can be used as an effective and economic tool to the Forming of single parts with different shapes and is cost-effective.