This paper presents the results of experimental research on the fabrication of thin-walled panels with longitudinal stiffening ribs by the single point incremental sheet forming technique. The bead-stiffened panels were made of Alclad 2024-T3 aluminium alloy sheets commonly used in aircraft structures. The influence of forming parameters and tool strategy on surface quality and the possibility of obtaining stiffening ribs with the required profile and depth was tested through experimental research. Two tool path strategies, spiral with continuous sinking and multi-step z-level contouring, were considered. The results of the experiments were used to verify the finite element-based numerical simulations of the incremental forming process. It was found that the main parameter which influences the formability of test sheets is the tool path strategy; the tool path strategy with multi-step z-level contouring allowed the rib to be formed to a depth of 3.53 mm without risk of cracking. However a greater depth of rib equal of 5.56 mm was achieved with the continuous tool path. The tool path strategy was also the main parameter influencing the surface finish of the drawpiece during the single point incremental forming process.

This study aims to determine optimal forming parameters for Incremental Sheet Forming process Commercially Pure titanium Grade 2 sheets in terms of formability improvement, force reduction, and efficiency of forming. Based on the central composite design, data were collected during 20 runs and then variation analysis was performed. The experiments were performed on a 3 axis CNC milling machine equipped with a Kistler dynamometer plate. Subsequently, regression models have been developed to describe process responses by input factors. As crucial parameters, the relative velocity and step size of the tool that affect the forming force and the height of the fracture have been determined. Finally, the application of optimization algorithm has emerged optimal input factors in terms of selected multi-criteria goal. The results of this study suggest that there is a process window that allows the formation of 45° wall angle drawpieces of commercially pure titanium Grade 2.