Profile forming of sheet metal is a special technique that offers flexibility and cost-effectiveness in the metal forming process, requiring no high capacity presses or set of dies, thus meeting the ever increasing demand for small batch production and rapid prototyping. This paper demonstrates the formation of sheet metal part using the CNC controlled hemispherical tool and analyses the various parameters underlying this mechanism - like maximum wall angle, surface roughness (Ra) and thinning of sheet. Analysis of the microstructure is carried out using Scanning electron microscopy and Energy-dispersive X-ray spectroscopy microanalysis test. In this study, Aluminium sheet of grade Al 3003(O) with 1mm and 1.25 mm thickness is used as a work piece. The paper also presents an explicit numerical simulation using the standard finite element code ABAQUS and the experimental and numerical results are validated.