Efficiency Analysis of Incremental Forging Processes on Flat Surfaces

Incremental forging processes produce permanent deformations by means of repeated localized compressions of the material in the work piece. These processes has interest from technological point of view because they can be carried out in CNC machines with more flexibility and lower forces requirements than in conventional forging processes. The purpose of this work is the analysis of efficiency of the incremental forming process of flat surfaces by means of simple tools, particularly ball end tools that are capable of forming the surface with lower axial forces. Then the ball-rolling incremental forging process has been investigated and a series of tests have been conducted in order to evaluate the forces produced during the deformation of the surfaces and the feasibility of the process.