Incremental Forming of Sandwich Panels


Article Preview

This paper presents a first investigation of the applicability of incremental sheet forming (ISF) to sandwich panels. Two initial tests on various sandwich panel designs established that sandwich panels which are ductile and incompressible are the most suitable for the process. Further tests on a sandwich panel with mild steel face plates and a continuous polypropylene core demonstrated that patterns of deformation and tool forces followed similar trends to a sheet metal. It is concluded that, where mechanically feasible, ISF can be applied to sandwich panels using existing knowledge of sheet metals with the expectation of achieving similar economic benefits. Potentially this will increase the range of applications for which sandwich panels are viable.



Main Theme:

Edited by:

F. Micari, M. Geiger, J. Duflou, B. Shirvani, R. Clarke, R. Di Lorenzo and L. Fratini




K.P. Jackson et al., "Incremental Forming of Sandwich Panels", Key Engineering Materials, Vol. 344, pp. 591-598, 2007

Online since:

July 2007




[1] D. Zenkert: An Introduction to Sandwich Construction, The Chameleon Press Ltd, London, United Kingdom (1995).

[2] R. Gustavsson: Formable sandwich construction material and use of the material as construction material in vehicles, refrigerators, boats etc., World Intellectual Property Organization, WO 98/01295 (1998).

[3] T.W. Clyne and A.E. Markaki: Ultra light stainless steel sheet material, U.S. Patent 10/000, 117 (2001).

[4] D. Contorno, et al.: Forming of aluminium foam sandwich panels: Numerical simulations and experimental tests, J. Materials Processing Technology, Vol. 177 1-3 (2006), pp.364-367.


[5] M. Landert: Forming behaviour of metal sandwich sheets, PhD Thesis, Department of Materials Science and Metallurgy, Cambridge University (2006).

[6] D. Mohr: On the role of shear strength in sandwich sheet forming, International Journal of Solids and Structures, Vol. 42 (2005), pp.1491-1512.


[7] K.J. Kim, et al.: Formability of AA5182/polypropylene/AA5182 sandwich sheets, Journal of Materials Processing Technology, Vol. 139 (2003), pp.1-7.


[8] E. Leszak: Apparatus and process for incremental dieless forming, Patent US3342051A1 (1967).

[9] L. Filice, et al.: Analysis of Material Formability in Incremental Forming, Annals of the CIRP, Vol. 51/1/2002 (2002), pp.199-202.


[10] S. Junk, et al.: Forming Strategies and Tools in Incremental Sheet Forming, SheMet, University of Ulster, Ireland (2003), pp.57-64.

[11] T.J. Kim and D.Y. Yang: Improvement of formability for the incremental sheet metal forming processes, International Journal of Mechanical Sciences, Vol. 42 (2000), pp.1271-1286.


[12] J.J. Park and Y.H. Kim: Fundamental Studies on the Incremental Sheet Metal Forming Technique, Journal of Materials Processing Technology, Vol. 140 (2003), pp.447-453.


[13] J.M. Allwood, et al.: A structured search for applications of the incremental sheet forming process by product segmentation, Proc I Mech E Part B J Eng Manuf, Vol. 219(2) (2005), pp.239-244.

[14] G. Ambrogio, et al.: Analysis of the economical effectiveness of incremental forming: an industrial case study, Proc. VI AITeM Conference, (2003).

[15] G. Hirt, et al.: Economical and ecological benefits of CNC incremental sheet forming (ISF), 9th International Workshop on Ecology and Economy in Manufacturing, ICEM 2003, Miskolc, Hungary (2003), p.

[16] J. Jeswiet, et al.: Forces in Single Point and Two Point Incremental Forming, SheMet '05, Erlangen, Germany (2005), pp.449-456.


[17] H. Iseki: An approximate deformation analysis and FEM analysis for the incremental bulging of sheet metal using a spherical roller, Journal of Materials Processing Technology, Vol. 111 (2001), pp.150-154.


[18] O. Bologa, et al.: Experimental research for determining the forces on incremental sheet forming process, 8th ESAFORM Conference, Cluj-Napoca, Romania (2005), pp.317-320.

[19] J. Duflou, et al.: Force Measurements for Single Point Incremental Forming: an Experimental Study, SheMet '05, Erlangen, Germany (2005), pp.441-448.


[20] D. Young and J. Jeswiet: Wall thickness variations in single-point incremental forming, J Engineering Manufacture, Vol. 218 Part B (2004), pp.1453-1459.


[21] G. Ambrogio, et al.: Sheet Thinning Prediction in Single Point Incremental Forming, SheMet '05, Erlangen, Germany (2005), pp.479-486.


[22] J.M. Allwood, et al.: The increased forming limits of incremental sheet forming processes, SheMet 2007, Palermo, Italy (2007), p.