In this work, the deformation of material and fracture mechanism during the incremental sheet forming process experimentally investigated. The mechanism of deformation is dependent on the process parameters. The present work experimentally explains how the tool radius, step size, and feed rate affect the failure mode during two-point incremental sheet forming. Experimental work achieved to examine the failure modes and analyses the reasons. The deformation of the material in two-point incremental sheet forming is a compound of stretching, shearing, squeezing and bending of material through a deformation zone. The experimental plan based on eighteen experiments cover all the conditions leading to the appearance of failure. The results showed an increasing tool radius and step size the behaviour of failure changes from crack without previous necking to crack with necking. The result showed four types of failure that were found during the TPIF process and identify the factors that lead to their appearance.
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