Abstract
The nature and magnitude of residual stresses affect the performance and service life of the formed components. The state of residual stresses in the axisymmetric shapes have been characterized in Single Point Incremental Sheet Forming (SPIF). However, any study detailing thorough distribution of residual stresses on an asymmetrical shape has not been reported. In the present work, a detailed analysis pertaining to the distribution of residual stresses on an asymmetrical pyramid and stress-parameters relationship (s) are reported. The maximum stresses were induced in the smaller face (or side) of the pyramid followed by the region(s) bordering the edges/corners of the larger face, while the minimum stresses were induced at the bottom of the pyramid. The maximum compressive stresses ranged from −11 MPa to−292 MPa, and the maximum tensile stresses ranged from +6 MPa to +341 MPa. The cause-effect analysis reveals that the diameter and wall angle were the most influential process parameters. Further, as measured on the face center, the stresses varied from +1050 MPa (max tensile) to −650 MPa (max compressive). The results will prove helpful for the process and product design.