A Simple and Low-Cost Lubrication Method for Improvement in the Surface Quality of Incremental Sheet Metal Forming

The incremental sheet forming technology as a flexible forming process is often used to fabricate parts with small batches or individuation. However, the lubrication of this technology is usually difficult and complex due to the rigidity in the contact between tool and sheet. In this work, a novel lubrication method with graphite grease/oil is adopted to fabricate parts with aluminum in incremental sheet forming, which is simple and low-cost compared to previous methods. Meanwhile, other two lubrication methods, such as oil lubrication and graphite lubrication, are adopted as control groups. The surface roughness profile and the surface morphology obtained by the new method are both better than that obtained by control groups. Moreover, machining and step-down traces of the forming surface of specimens fabricated, thickness distribution, and forming force could be availably improved with the novel lubrication method.