Single point incremental forming of cold-rolled polycarbonate sheets

The present work aims to examine the influence of a preliminary cold-rolling of polycarbonate sheets on the single point incremental forming of this outstanding engineering material. Experimental tests involved the manufacture of incremental formed pyramid frusta, obtained by undeformed and cold-rolled polycarbonate sheets (with different rolling reductions), for the same thickness; these components were manufactured by a high commonly used computer numerically controlled machine, a simple-shaped tool and a sheet clamping system. The comparison was made over different significant features of the process under exam, concerning the forming forces and the occurrence of failures and defects on the components, in order to weigh up the possibility of using anisotropic cold-rolled rather than isotropic undeformed thermoplastic sheets, depending on the design requirements of the product.