Hybrid forming-machining technology is a combination of two emerging manufacturing technologies: thin structural machining and incremental forming. The process can be used to fabricate highly complex geometry workpieces. The main difficulty with this process is controlling dimensional accuracy which is caused by springback phenomenon. In this work, the springback phenomenon was studied in the hybrid forming-machining process. For this purpose, a block was first machined to produce a thin wall. The wall was then bent using single point incremental forming. The results showed that the forming tool path had a considerable effect on the dimensional accuracy of the workpiece. Therefore, the main focus of this study was to optimize the tool path with the purpose of improving dimensional accuracy. The top-down and bottom-up forming strategies were used to study the effect of these strategies on springback. It was observed that the bottom-up strategy could lead to smaller springback. In addition, the closer the forming tool to the workpieces root, the smaller the springback. However, the workpiece fails if the forming tool approache to the workpiece root. Therefore, a systematic experimental procedure was suggested to identify the optimum tool path on which the workpiece dose not fail and the springback is also kept to a minimum. In order to compensate springback, the displacement adjustment method and reverse displacement compensation algorithm were employed. Abaqus finite element package was used to modify the tool path and implement the springback compensation method. A python script was written to run a simulation using the initial tool path and predict the final workpiece shape after springback. The predicted profile after springback was compared with the target profile. A new tool path was suggested by the the algorithm if there was a discrepancy between the two profiles. The experimental results showed that the developed sterategy considerably reduces springback. Keywords :Deformation machining, Springback, Displacement adjustment, Incremental forming
