Incremental Sheet Forming (ISF) is a sheet metal forming process, which relies on minimum part-specific tooling. Extra Deep Drawn (EDD) steel has been used for making door inners, dash panels, bodyside inners, etc. due to its good weldability and relatively low yield strength. However, to date very limited work is reported on ISF of EDD steel. Besides, no work, which exhaustively discusses the practicability of EDD steel for effectual incremental forming of components, is found to be reported. The present work discusses the ISF of EDD steel sheets and examines the limitations of ISF in forming the parts out of 1.0 mm thick EDD steel sheets. Two geometries, i.e., ellipsoidal cone (with varying wall angle) and truncated cone (with constant wall angle) were used as test cases to evaluate the formability of EDD steel sheets, in terms of Critical Wall Angle (CWA). Further, the formability of EDD steel with ISF is evaluated using both strain-based and stress-based forming limit curves. The thickness distribution, geometrical accuracy, forming forces, and surface roughness and hardness are evaluated in the formed components. The work, through numerical simulations and experimental analyses, investigates the process capabilities of ISF to form the EDD steel sheets in terms of formability, thickness distribution, geometrical accuracy, forming forces, and surface roughness and hardness to ascertain the scope of the proposed process.

增量钣金成型 (ISF) 是一种钣金成型工艺，它依赖于最少的零件特定工具。由于其良好的可焊性和相对较低的屈服强度，超深拉 (EDD) 钢已被用于制造车门内件、仪表板、车身侧内件等。然而，迄今为止，关于 EDD 钢 ISF 的报道非常有限。此外，没有发现详尽讨论 EDD 钢在有效渐进成形组件中的实用性的工作报告。目前的工作讨论了 EDD 钢板的 ISF，并检查了 ISF 在用 1.0 毫米厚的 EDD 钢板成型零件时的局限性。两种几何形状，即椭圆锥（具有不同壁角）和截锥（具有恒定壁角）作为测试案例来评估 EDD 钢板的成形性，临界壁角 (CWA)。此外，使用基于应变和基于应力的成形极限曲线来评估具有 ISF 的 EDD 钢的成形性。在成形部件中评估厚度分布、几何精度、成形力以及表面粗糙度和硬度。这项工作通过数值模拟和实验分析，在可成形性、厚度分布、几何精度、成形力、表面粗糙度和硬度方面研究了 ISF 形成 EDD 钢板的工艺能力，以确定拟议工艺的范围。并对成型部件的表面粗糙度和硬度进行评估。这项工作通过数值模拟和实验分析，在可成形性、厚度分布、几何精度、成形力、表面粗糙度和硬度方面研究了 ISF 形成 EDD 钢板的工艺能力，以确定拟议工艺的范围。并对成型部件的表面粗糙度和硬度进行评估。这项工作通过数值模拟和实验分析，在可成形性、厚度分布、几何精度、成形力、表面粗糙度和硬度方面研究了 ISF 形成 EDD 钢板的工艺能力，以确定拟议工艺的范围。