A method for determining efficiency parameters based on efficiency-quality graph in incremental sheet forming

This study reveals the mechanisms by which efficiency parameters affect surface quality, mechanical properties, and configuration offset in incremental sheet forming (ISF), focusing on surface morphology and microstructural evolution. By constructing an efficiency-quality graph, a method is developed to determine efficiency parameters that balance quality and efficiency synergistically. The results show that increasing the step depth (Z) and decreasing the feed rate (v) intensify plowing and adhesion effects at the interface, degrading surface quality and enriching the presence of {001}<100> Cube and {112}<111> Copper textures, while the cross-sectional crystal orientation remains unaffected. Additionally, increasing Z enlarges grain size and reduces high-angle grain boundaries (HAGBs), amplifying micro-stress and defects, which deteriorates mechanical properties and increases configuration offset. Conversely, increasing v has minimal impact on mechanical properties but significantly increases configuration offset due to the rise in HAGBs, micro-stress, and defects. The efficiency-quality graph elucidates the complex synergistic relationship between forming efficiency and comprehensive quality of the formed parts, and the optimal efficiency parameters are identified by considering the priority order of different quality dimensions. Specifically, when prioritizing surface quality and hardness, the optimal parameters are Z = 0.1 mm and v = 5000 mm/min; when prioritizing configuration offset, the optimal parameters are Z = 0.1 mm and v = 1000 mm/min. Therefore, this study provides a comprehensive method for evaluating efficiency parameters in ISF, emphasizing the importance of balancing efficiency with quality.