Review on the influence of process parameters in incremental sheet forming

Prototyping through incremental sheet forming is emerging as a latest trend in the manufacturing industries for fabricating personalized components according to customer requirement. In this study, a laboratory scale single-point incremental forming test setup was designed and fabricated to deform AA6061 sheet metal plastically. In addition, response surface methodology with Box–Behnken design technique was used to establish different regression models correlating input process parameters with mechanical responses such as angle of failure, part depth per unit time and surface roughness. Correspondingly, the regression models were implemented to optimize the input process parameters, and the predicted responses were successfully validated at the optimal conditions. It was observed that the predicted absolute error for angle of failure, part depth per unit time and surface roughness responses was approximately 0.9%, 4.4% and 6.3%, respectively, for the optimum parametric combination. Furthermore, the post-deformation responses from an optimized single point incremental forming truncated cone were correlated with microstructural evolution. It was observed that the peak hardness and highest areal surface roughness of 158 ± 9 HV and 1.943 μm, respectively, were found near to the pole of single-point incremental forming truncated cone, and the highest major plastic strain at this region was 0.80. During incremental forming, a significant increase in microhardness occurred due to grain refinement, whereas a substantial increase in the Brass and S texture component was responsible for the increase in the surface roughness.

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Review of the effect of process parameters on performance measures in the incremental sheet forming process

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405420961215 ◽

2020 ◽

pp. 095440542096121

Author(s):

Ashish Gohil ◽

Bharat Modi

Keyword(s):

Process Parameters ◽

Metal Forming ◽

Lead Time ◽

Incremental Forming ◽

Low Cost ◽

Research Work ◽

Sheet Forming ◽

Commercial Production ◽

Incremental Sheet Forming ◽

Forming Process

Incremental sheet forming process has developed the interest of researchers in the field of sheet metal forming due to high formability and capability to produce prototypes of new products at low cost and minimum lead time. Research work is going on in various front to enhance the process capabilities so that it can be explored for commercial production. In this article, progress and recent development in the field of incremental forming has been reviewed and presented for the benefit of practicing engineers and industry. The effect of various process parameters on the performance of the process have been summarized in this paper. Moreover, the issues which need attention are discussed towards the conclusion of this paper.

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Incremental sheet forming of thermoplastics: a review

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-06056-5 ◽

2020 ◽

Vol 111 (1-2) ◽

pp. 565-587

Author(s):

Hui Zhu ◽

Hengan Ou ◽

Atanas Popov

Keyword(s):

Process Parameters ◽

Flexible Manufacturing ◽

Sheet Forming ◽

Incremental Sheet Forming ◽

Metallic Materials ◽

Processing Conditions ◽

Geometric Accuracy ◽

Significant Progress ◽

Research Directions ◽

Made In

Abstract Incremental sheet forming (ISF) is a promising flexible manufacturing process, which has been tested in sheet forming of various metallic materials. Although ISF-based forming of thermoplastics is relatively new, it has drawn considerable interests and significant progress has been made in recent years. This paper presents a review of concurrent research on the emerging trend of thermoplastic-focused ISF processes. Attention is given to the processing conditions including process setup, process parameters and forming forces. The deformation mechanism and failure behaviour during ISF of thermoplastics are evaluated, which leads to detailed discussions on the formability, effect of different process parameters and the forming quality such as geometric accuracy, surface finish and other consideration factors in ISF of thermoplastics. A comparison of important similarities and differences between ISF of thermoplastic and metallic materials is made. Finally, a brief discussion is provided on the technical challenges and research directions for ISF of thermoplastic materials in the future.

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Investigating the Effect of Process Parameters in Incremental Sheet Forming Process

Advances in Civil and Industrial Engineering - Data-Driven Optimization of Manufacturing Processes ◽

10.4018/978-1-7998-7206-1.ch003 ◽

2021 ◽

pp. 24-36

Author(s):

Manish Oraon ◽

Manish Kumar Roy ◽

Vinay Sharma

Keyword(s):

Surface Roughness ◽

Process Parameters ◽

Sheet Forming ◽

Incremental Sheet Forming ◽

Forming Process ◽

Batch Production ◽

Force Microscopy ◽

Atomic Force ◽

Roughness Analysis ◽

Step Down

Incremental sheet forming (ISF) is an emerging technique of sheet metal working that comes into the picture in the last two decades. The ISF involved the forming of shapes without using the dedicated dies. ISF is suitable for customized products, rapid prototyping, and low batch production. The study aims to investigate the effect of process parameters on the surface roughness. The experiments are conducted on aluminum AA3003-O grade with six parameters, and the trials are performed according to the design of experiment (DOE). The atomic force microscopy (AFM) technique is used for measuring the surface roughness. Analysis of variance (ANOVA) is used for analyzing the effect of process parameters in ISF. The result shows that the step-down size, feed rate of the tool, and wall angle are significant process parameter and their contributions for ISF are 85.86%, 1.12%, and 12.29%, respectively.

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Numerical Simulation on the Effect of Process Parameters for Incremental Sheet Forming

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.158 ◽

2010 ◽

Vol 97-101 ◽

pp. 158-161 ◽

Cited By ~ 1

Author(s):

Qin Qin ◽

Di Ping Wu ◽

Mi Li ◽

Yong Zang

Keyword(s):

Process Parameters ◽

Rapid Prototype ◽

Sheet Forming ◽

Incremental Sheet Forming ◽

Layered Manufacturing ◽

Forming Process ◽

Step Size ◽

Flexible Technology ◽

Vertical Step ◽

Forming Angle

Incremental sheet forming (ISF), based on the ‘layered manufacturing’ principle of rapid prototype manufacturing technology, is an innovative and highly flexible technology for forming complex shaped parts without the need for costly dies. This paper presents a numerical investigation on the influence of forming process parameters by modeling the forming process. ANSYS/LS-DYNA has been used for the simulation. The results of study show that small vertical step size can improve the accuracy of the forming. Moreover, large forming angle can increase plastic strain and the four screwdown point optimization paths is an effective method to increase the accuracy of the formed sheet.

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Efficiency of optimization algorithms on the adjustment of process parameters for geometric accuracy enhancement of denture plate in single point incremental sheet forming

Neural Computing and Applications ◽

10.1007/s00521-019-04354-y ◽

2019 ◽

Vol 32 (13) ◽

pp. 8829-8846 ◽

Cited By ~ 1

Author(s):

Manel Sbayti ◽

Riadh Bahloul ◽

Hedi Belhadjsalah

Keyword(s):

Process Parameters ◽

Single Point ◽

Optimization Algorithms ◽

Sheet Forming ◽

Incremental Sheet Forming ◽

Geometric Accuracy ◽

Accuracy Enhancement ◽

Denture Plate

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Influence of process parameters on the residual stress state and properties in disc springs made by incremental sheet forming (ISF)

Forschung im Ingenieurwesen ◽

10.1007/s10010-021-00491-w ◽

2021 ◽

Author(s):

Muhammad Junaid Afzal ◽

Ramin Hajavifard ◽

Johannes Buhl ◽

Frank Walther ◽

Markus Bambach

Keyword(s):

Residual Stress ◽

Stress State ◽

Residual Stresses ◽

Process Parameters ◽

Shot Peening ◽

Sheet Forming ◽

Incremental Sheet Forming ◽

Installation Space ◽

Residual Stress State ◽

Compressive Residual Stresses

AbstractDisc springs are machine elements that are used when high forces need to be supplied and in limited installation space. They need to fulfil high demands on the stability of the spring characteristics, reliability and lifetime. In corrosive environments, metastable austenitic stainless steels (MASS) disc springs are often used. Tensile stresses that occur during service limit the lifetime of disc springs. Usually, their durability is enhanced by generating favorable compressive residual stresses using shot peening operations. Such operations lead to extra efforts and additional production costs. In this study, the adaptive and targeted generation of residual stresses via incremental sheet forming (ISF) is investigated as alternative to shot peening focusing on EN 1.4310 and EN 1.4401 stainless steel. Previous work has shown that ISF is capable of controlling the radial and tangential stresses in the springs. However, no analysis of the influence of the residual stress state in the rolled sheet strips and the ISF process parameters was performed. The goal of the current work is to analyze the evolution of residual stress during rolling and subsequent incremental forming of disc springs. In order to examine the role of dissipation and temperature increases in the rolling process, sheet blanks rolled at room and elevated temperature are analyzed. The characteristics of the compressive residual stresses induced by ISF are studied for different process parameters. X‑ray diffraction is used to investigate the buildup of these stresses. Using ISF, the generation of compressive residual stresses can be integrated into the forming process of disc springs, and further post-treatment may be skipped. The results show that the residual stress state in the rolled material is crucial, which requires tight control of the rolling temperature. Another result is that ISF is able to yield high compressive residual stresses and improved spring characteristics when small tool diameters and step-down values are used.

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RSM and BPNN Modeling in Incremental Sheet Forming Process for AA5052 Sheet: Multi-Objective Optimization Using Genetic Algorithm

Metals ◽

10.3390/met10081003 ◽

2020 ◽

Vol 10 (8) ◽

pp. 1003 ◽

Cited By ~ 2

Author(s):

Xiao Xiao ◽

Jin-Jae Kim ◽

Myoung-Pyo Hong ◽

Sen Yang ◽

Young-Suk Kim

Keyword(s):

Genetic Algorithm ◽

Process Parameters ◽

Sheet Forming ◽

Incremental Sheet Forming ◽

Thickness Reduction ◽

Multi Objective Optimization ◽

Minimum Thickness ◽

Multi Objective ◽

Forming Angle ◽

Tool Diameter

In this study, the response surface method (RSM), back propagation neural network (BPNN), and genetic algorithm (GA) were used for modeling and multi-objective optimization of the forming parameters of AA5052 in incremental sheet forming (ISF). The optimization objectives were maximum forming angle and minimum thickness reduction whose values vary in response to changes in production process parameters, such as the tool diameter, step depth, tool feed rate, and tool spindle speed. A Box–Behnken experimental design was used to develop an RSM and BPNN model for modeling the variations in the forming angle and thickness reduction in response to variations in process parameters. Subsequently, the RSM model was used as the fitness function for multi-objective optimization of the ISF process using the GA. The results showed that RSM effectively modeled the forming angle and thickness reduction. Furthermore, the correlation coefficients of the experimental responses and BPNN predictions of the experiment results were good with the minimum value being 0.97936. The Pareto optimal solutions for maximum forming angle and minimum thickness reduction were obtained and reported. The optimized Pareto front produced by the GA can be a rational design guide for practical applications of AA5052 in the ISF process.

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