Localized Manipulation of Martensite Transformation in Double-Sided Incremental Forming by Varying the Deformation Path

Abstract

Incremental sheet metal forming is known for its high flexibility, making it suitable for fabricating low-batch, highly customized complex parts. In this article, a localized multipass toolpath referred to as localized reforming, with reverse forming in a region of interest, is employed within the double-sided incremental forming (DSIF) process to manipulate the mechanical properties of a truncated pyramid formed from austenitic stainless steel sheet, SS304, through deformation-induced martensite transformation. DSIF forms a clamped sheet through localized deformations by two opposing tools. The toolpath effect in localized reforming is examined in terms of martensite transformation, geometrical accuracy, and thickness distribution. The results are compared with a conventional toolpath, i.e., forming in a single pass. The results show that varying toolpaths lead to different martensite transformation levels, while final geometry and thickness remain similar. The study demonstrates that localized reforming significantly increases martensite transformation in the specified region, i.e., the center of the pyramid wall, to ∼70%, with a martensite fraction remaining around 25% elsewhere. In comparison, using a single pass forming toolpath leads to a decreasing martensite fraction from the base of the pyramid toward the apex, due to the heat generated, with values <10% along the entire wall. Through finite element simulation, it is shown that the increase in martensite transformation of the region of interest is with the plastic deformation accumulation during the reverse pass. These findings highlight the potential to tailor mechanical properties in specific areas using a reforming toolpath in DSIF.