Force Measurement in Pyramid Shaped Parts with a Spindle Mounted Force Sensor

Forces are measured in Single Point Incremental Forming with a spindle mounted sensor. Results for AA3003 aluminum cones and pyramids are shown. Forces are measured for parts with a 75° forming angle, at which shear cracks are expected to occur. Forces in the three directions are measured on the spindle with force spikes being observed when the tool changes direction at pyramid corners, and reductions in force when stepping between contours. There is also a force variation as the forming tool moves along the pyramid wall. A comparison is made between the forces measured for cones and pyramids.