Multi-pass deformation design for incremental sheet forming: Analytical modeling, finite element analysis and experimental validation.

Highlights: [•] Two open-loop analytical models for multi-pass deformation design have been developed and tested given the predicted thickness strain of the final part as a main parameter using the assumption of shear deformation. [•] A comprehensive methodology for closed-loop multi-stage deformation pass design incorporating two developed models is proposed. [•] FEA and experimental tests have been performed to validate the comprehensive closed-loop design methodology with two analytical models. [•] The proposed closed-loop pass design methodology with M2 is proved to be an effective approach to designing multi-stage deformation passes in order to quantitatively control the material flow. [ABSTRACT FROM AUTHOR]