Influence of geometric configurations on friction characteristics during incremental forming process of AA5052 sheet metal

The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters, along with plastic strain, contact pressure, and area. The interface promotes lubrication and support when wall angles were ≤ 40°, a 0.5 mm-thin sheet was used, and a 10 mm-large tool radius was employed. This mainly results in micro-plowing and plastic extrusion flow, leading to lower friction coefficient. However, when wall angles exceed 40°, significant plastic strain roughening occurs, leading to inadequate lubrication on the newly formed surface. Increased sheet thickness and decreased tool radius elevate contact pressure. These actions trigger micro-cutting and adhesion, potentially leading to localized scuffing and dimple tears, and higher friction coefficient. The friction mechanisms remain unaffected by the part's plane curve features. As the forming process progresses, abrasive wear intensifies, and surface morphology evolves unfavorably for lubrication and friction reduction.