M. Esmailian - Faculty of Mechanics, Malek Ashtar University of Technology, Iran
M. Honarpisheh - Faculty of Mechanical Engineering, University of Kashan, Kashan, Iran
A. Gheysarian - Faculty of Mechanical Engineering, University of Kashan, Kashan, Iran

Incremental forming is one of the new forming methods. Single-point incremental forming (SPIF) has shown significant potential for forming complex metal parts. In the single-point incremental forming, a spherical tool head moves along a pre-defined path to form the desired geometry. The aim of this study is to optimize the fracture depth and forming forces of the three-layer metal-polymer sheet by using the single-point incremental forming process. By using response surface methodology (RSM), a series of experiments were designed in which tool diameter, step down and spindle speed were considered as process input parameters. The influencing parameters in fracture depth and forming forces have been identified by using statistical tools (response table, main effect diagram and ANOVA). Analysis of variance was used to show potential differences between the means of variables by testing the population value in each sample, which enables it to show the effects of input variables on output variables. The results show that the forming forces increased and the formability decreased by increasing the step down and the tool diameter. The highest forming force is ۱۴۷۶ N and the lowest value is ۱۰۴۵ N. Similarly, the highest fracture depth is ۸.۸ mm and the lowest is ۷.۱ mm. The best conditions are achieved when spindle speed is ۲۳۴۰.۹ rpm, tool diameter is ۷.۵۱۹۷۸ mm, and vertical step is ۰.۳۲۹۵۵۲ mm. In this condition, the fracture depth is ۸.۵۰۵۵۲ mm and the forming force is ۷۷۶.۰۳ N.

Incremental sheet forming, Metal–polymer three‑layer sheet fracture depth, ANOVA, Forming Force, Fracture depth