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Cross-Scale Correlation Analysis Between Forming Quality and Microstructural Response During SPIF of the Al 1060
Xinyue Zhang1, Xiaojing Zhu1, Yuhuai Wang2,3
1School of Mechanical & Electrical Engineering, China Jiliang University, Hangzhou 310018, China.
Materials (Basel, Switzerland)
|July 28, 2026
Summary
This study links single-point incremental forming (SPIF) quality to microstructural changes using a novel cross-scale analysis. It reveals how plastic deformation affects material properties, aiding in predicting and controlling SPIF accuracy.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Processes
Background:
- Single-point incremental forming (SPIF) causes localized plastic deformation, leading to reduced thickness, geometric inaccuracies, and microstructural changes.
- Understanding the link between forming quality and microstructural evolution is crucial for optimizing SPIF processes.
Purpose of the Study:
- To develop and apply a cross-scale analysis framework to correlate SPIF forming quality with microstructural responses.
- To investigate the relationship between plastic strain, dislocation density, and microstructural evolution in Al 1060 during SPIF.
Main Methods:
- Integrated finite element simulation with Kocks-Mecking (K-M) based statistically stored dislocation (SSD) density inference.
- Employed metallographic observation and electron backscatter diffraction (EBSD) for characterization.
- Calibrated K-M model using Voce hardening and Taylor relation, correlating simulated plastic strain (PEEQ) with SSD density.
Main Results:
- Inferred SSD density saturated at 1.55 × 10^13 m^-2, with high-density regions expanding during forming, consistent with EBSD observations.
- Average grain size decreased from 30.4 μm to 21.9 μm, and medium-angle grain boundary fraction increased from 10.3% to 34.5%.
- Thickness reduction correlated with PEEQ, SSD storage, and grain refinement; geometrical deviation related to early deformation heterogeneity.
Conclusions:
- The developed cross-scale framework effectively links SPIF-induced plastic deformation to microstructural evolution.
- Findings provide a physically based approach for predicting and controlling geometrical accuracy in SPIF.
- The study highlights the importance of microstructural analysis for optimizing incremental forming processes.
