
The technology of incremental sheet-bulk metal forming (iSBMF) provides a resource-efficient approach for the near-net-shape manufacture of functional components featuring a load-adapted shape. For this reason, consecutive edge thickening and gear forming processes are experimentally developed, numerically investigated and analytically described. Due to the flexibility of the incremental procedure, different load paths can manufacture identical geometries. Concurrent, the strain hardening behavior of the workpiece material depends on the load path. This research focuses a targeted adjustment of the mechanical properties within the component by a variation of the load path. Moreover, the kinematic-depending geometrical accuracy of iSBMF gear elements is determined. As the mechanical adjustability is limited to the strain hardening potential of the material, an additional hybrid approach is investigated. This approach enables the grading of mechanical properties by layering sheets with different strength and strain hardening behavior. Moreover, a reduced averaged strength of the stack reduces the tool load appearing on the filigree forming tools. Moreover, a significant load reduction is examined when an electrical current is introduced in the forming zone. This force reduction provides the basis for the iSBMF of high strength materials. Thus, the conflict between a load reduction and the preservation of strain hardening is analyzed.
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