Incremental sheet forming is a flexible forming process where a tool is programmed to follow a pre-determined tool path to create sheet metal parts. Without using complex tool and die, the process can generate various part geometries directly from CAD models and CNC codes, and is ideal for rapid prototyping and low volume production. Modeling incremental sheet forming and predicting forming forces can significantly benefit product design and process development. Existing force prediction methods are either inaccurate or too time consuming. In this paper, an efficient force prediction strategy was proposed based on experimental observations of forming force patterns. It was found that by creating a near finished part geometry as a starting point of numerical simulation, forming forces can be predicted with satisfactory accuracy and efficiency. The proposed strategy was validated with forming of a truncated pyramid and was further demonstrated in forming of parts having different geometries. As the proposed simulation strategy can be completed in a fraction of the full simulation time, it can be adopted to guide the design and development of incremental sheet forming parts.
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