A new method for multi-pass single-point incremental forming of vertical wall square box with small corner radius

According to the sine law, a vertical wall square box cannot be formed by incremental forming with a single-pass process; or rather it must be created with multi-pass processes. It is found that successful forming not only depends on the forming half-apex angle θ of a conical box, but also on the corner radius r. The metal will pile up on the corner for a square box with a small corner radius when the tool paths are unreasonable. Therefore, the tool paths with a gradually reduced corner radius are adopted to overcome this problem. A vertical wall square box with a small corner radius is successfully created.