The mechanical properties and the operating life of a formed component are highly dependent on the residual stress state. There is always a high magnitude of residual stresses in the components formed by incremental sheet forming (ISF) due to the localized deformation mechanism. Hence, a thorough understanding of the generation of the residual stresses by ISF is necessary. This study investigates the residual stress generation mechanism for two process variants of ISF, i.e., Single Point Incremental Forming (SPIF) and Two Point Incremental Forming (TPIF). This understanding is used to control and targetedly generate the residual stresses to improve the part performance. In this regard, the residual stress state in a truncated cone geometry manufactured using SPIF and disc springs manufactured using TPIF was experimentally analyzed. Validated numerical models for both process variants were developed to study the residual stresses in detail. The residual stress state in SPIF is such that the tool contact side develops tensile residual stresses and the non-contact side undergoes compressive residual stresses. The tool step-down variation was used to control residual stresses and improve the fatigue strength of truncated cones manufactured using SPIF. For TPIF, two different forming strategies were used to analyze the residual stress generation mechanism and the role of major process parameters. The residual stresses for TPIF are pre-dominantly compressive in both directions of forming tool motion. For both process variants of the ISF process, it is shown that the residual stresses can be beneficially utilized to improve mechanical properties of the components.

成型部件的机械性能和使用寿命在很大程度上取决于残余应力状态。由于局部变形机制，在通过增量板材成形（ISF）形成的组件中始终存在很大的残余应力。因此，有必要对ISF产生残余应力有透彻的了解。这项研究调查了ISF的两个过程变量，即单点增量成型（SPIF）和两点增量成型（TPIF）的残余应力生成机理。这种理解可用于控制并有针对性地产生残余应力，以改善零件性能。在这点上，通过实验分析了使用SPIF制造的截锥几何形状和使用TPIF制造的碟形弹簧的残余应力状态。开发了两种工艺变量的经过验证的数值模型，以详细研究残余应力。SPIF中的残余应力状态使得工具接触侧产生拉伸残余应力，而非接触侧则承受压缩残余应力。工具的降级变化用于控制残余应力并提高使用SPIF制造的截锥的疲劳强度。对于TPIF，使用两种不同的成形策略来分析残余应力的产生机理和主要工艺参数的作用。TPIF的残余应力主要在成型工具运动的两个方向上都是压缩的。对于ISF工艺的两种工艺变体，都表明可以有效利用残余应力来改善组件的机械性能。