scholarly journals Study of the Effect of Process Parameters on Surface Profile Accuracy in Single-Point Incremental Sheet Forming of AA1050-H14 Aluminum Alloy

2020 ◽  
Vol 2020 ◽  
pp. 1-14
Author(s):  
Abdulmajeed Dabwan ◽  
Adham E. Ragab ◽  
Mohamed A. Saleh ◽  
Saqib Anwar ◽  
Atef M. Ghaleb ◽  
...  
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Surface Profile ◽  
Sheet Thickness ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Tool Diameter ◽  
Profile Accuracy

Single-point incremental forming is an innovative flexible and inexpensive technique to form sheet products when prototypes or small batches are required. The process allows complex geometries to be produced using a computer numerical control machine, eliminating the need for a special die. This study reports on the effects of four important single-point incremental forming process parameters on produced surface profile accuracies. The profile accuracy was estimated by measuring the side angle errors and surface roughness and also waviness and circularity of the product inner surface. Full factorial design of experiments was used to plan the study, and the analysis of variance was used to analyze and interpret the results. The results indicate that the tool diameter (d), step depth (s), and sheet thickness (t) have significant effects on the produced profile accuracy, while the feed rate (f) is not significant. As a general rule, thin sheets with greater tool diameters yielded the best surface quality. The results also show that controlling all surface quality features is complex because of the contradicting effects of, and interactions between, a number of the process parameters.

scholarly journals ANALYSIS OF THE SURFACE QUALITY OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING

2016 ◽  
Vol 19 (3) ◽  
Author(s):  
CRINA RADU ◽  
EUGEN HERGHELEGIU ◽  
ION CRISTEA ◽  
CAROL SCHNAKOVSZKY
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Metal Sheets ◽  
Vertical Step ◽  
Tool Diameter ◽  
Aluminium Metal

<p>The aim of the current work was to analyse the influence of the process parameters (tool diameter, size of the vertical step of tool, feed rate and spindle speed) on the quality of the processed surface, expressed in terms of roughness and macrostructure in the case of parts processed by single point incremental forming. The analysis was made on A1050 aluminium metal sheets. The obtained results revealed that the process parameters influence differently the surface quality, the worst influence being exerted by the increase of the vertical step of tool. </p>

scholarly journals Study on Thickness Thinning Ratio of the Forming Parts in Single Point Incremental Forming Process

2018 ◽  
Vol 2018 ◽  
pp. 1-11 ◽  
Author(s):  
Mingshun Yang ◽  
Zimeng Yao ◽  
Yan Li ◽  
Pengyang Li ◽  
Fengkui Cui ◽  
...  
Keyword(s):  
Deformation Zone ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Feeding Speed ◽  
Forming Angle ◽  
Tool Diameter ◽  
Thinning Rate

An excessive thickness-reducing ratio of the deformation zone in single point incremental forming of the metal sheet process has an important influence on the forming limit. Prediction of the deformation zone thickness is an important approach to control the thinning ratio. Taking the 1060 aluminum as the research object, the principle of thickness deformation in the single point incremental forming process was analyzed; the finite element model was established using ABAQUS. A formula with high accuracy to predict the deformation zone thickness was fitted with the simulation results, and the influences of process parameters, such as tool diameter, step down, feeding speed, sheet thickness, and forming angle, on thinning ratio were analyzed. The accuracy of the finite element simulation was verified by experiment. A method to control the thinning rate by changing the forming trajectory was proposed. The results showed that the obtained value by using the fitted formula is closer to the experimental results than that obtained by the sine theorem. The thinning rate of the deformation zone increases with the increase of tool diameter, forming angle, and sheet thickness and decreases with the increase of step down, while the feeding speed had no significant effect on the thinning ratio. The most important factor of the thinning ratio is the forming angle, and the thinning ratio can be effectively reduced by using the forming trajectory with a uniformly distributed pressing point.

STUDY ON FORMING FORCES OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING WITH DUMMY SHEET

2019 ◽  
Vol 14 (3) ◽  
Author(s):  
Vikas Sisodia ◽  
Shailendra Kumar
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Thickness ◽  
Single Point Incremental Forming ◽  
Forming Force ◽  
Step Size ◽  
Wall Angle ◽  
Influence Of Process Parameters

The present paper describes the experimental investigation on influence of process parameters on maximum forming force in Single Point Incremental Forming (SPIF) process using dummy sheet. Process parameters namely dummy sheet thickness, tool size, step size, wall angle and feed rate are selected. Taguchi L18 orthogonal array is used to design the experiments. From the analysis of variance (ANOVA) dummy sheet thickness, tool size, step size and wall angle are significant process parameters while feed rate is insignificant. It is found that as dummy sheet thickness, tool size, step size and wall angle increase magnitude of peak forming force increases while there is marginal decrease in forming force as feed rate increases. Predictive model is also developed for forming force. Validation tests are performed in order to check the accuracy of developed model. Optimum set of process parameters is also determined to minimize forming force. Experimental results are in good agreement with results predicted by the developed mathematical model.

Achieving maximum dimensional accuracy and surface quality at the shortest possible time in single-point incremental forming via multi-objective optimization

2018 ◽  
Vol 233 (3) ◽  
pp. 900-913 ◽  
Author(s):  
Abolfazl Taherkhani ◽  
Ali Basti ◽  
Nader Nariman-Zadeh ◽  
Ali Jamali
Keyword(s):  
Surface Quality ◽  
Sheet Metal ◽  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Multi Objective Optimization ◽  
Multi Objective ◽  
Design Variables

Single-point incremental forming is a novel and flexible method for producing three-dimensional parts from metal sheets. Although single-point incremental forming is a suitable method for rapid prototyping of sheet metal components, there are limitations and challenges facing the commercialization of this process. Dimensional accuracy, surface quality, and production time are of vital importance in any manufacturing process. The present study is aimed at selecting proper forming parameters to produce sheet metal parts which possess dimensional accuracy and good surface quality at the shortest time. Four parameters (i.e. tool diameter, tool step depth, sheet thickness, and feed rate) are chosen as design variables. These parameters are used for the modeling of the process using Group Method of Data Handing(GMDH) artificial neural networks. The data necessary for establishing empirical models are obtained from single-point incremental forming experiments carried out on a computer numerical control milling machine using central composite design. After the evaluation of the model accuracy, single- and multi-objective optimization are performed via genetic algorithm. The performance of the design variables of a tradeoff point corresponding to one of the experiments shows the efficiency and accuracy of the models and the optimization process. Considering the priorities of objective functions, a designer will be able to set proper process parameters.

scholarly journals Experimental Study the Effect of Tool Geometry on Dimensional Accuracy in Single Point Incremental Forming (SPIF) Process

2018 ◽  
Vol 21 (1) ◽  
pp. 108 ◽  
Author(s):  
Aqeel Sabree Bedan ◽  
Halah Ali Habeeb
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Dimensional Accuracy ◽  
Numerical Control ◽  
Tool Geometry ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Angle ◽  
Product Profile ◽  
Tool Diameter

Incremental forming is a flexible sheet metal forming process which performed by utilizes simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. One limitations of single point incremental forming (SPIF) process is the error occur between the CAD design and the product profile. This work presents the single point incremental forming process for produced pyramid geometry and studied the effect of tool geometry, tool diameter, wall angle, and spindle speed on the dimensional accuracy. Three geometries of forming tools were used in experimental work: ball end tool, hemispherical tool, and flat with round corner tool. The sheet material used was pure Aluminum (Al 1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The products dimensions were measured by utilized the dimensional sensor measuring instrument. The extracted results from the single point incremental forming process indicated the best acceptance between the CAD profile and product profile was found with the ball end tool and diameter of (10 mm), wall angle (50°) and the rotational speed of the tool was (800 rpm).

scholarly journals An Investigation Study of Tool Geometry in Single Point Incremental Forming (SPIF) and their effect on Residual Stresses Using ANOVA Model

2019 ◽  
Vol 14 (2) ◽  
pp. 1-13
Author(s):  
Aqeel S Sabree Bedan ◽  
Halah Ali H Habeeb
Keyword(s):  
Residual Stresses ◽  
Rotational Speed ◽  
Incremental Forming ◽  
Single Point ◽  
Numerical Control ◽  
Tool Geometry ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Wall Angle ◽  
Tool Diameter

Incremental forming is a flexible sheet metal forming process which is performed by utilizing simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. This work presents the single point incremental forming process for producing pyramid geometry and studies the effect of tool geometry, tool diameter, and spindle speed on the residual stresses. The residual stresses were measured by ORIONRKS 6000 test measuring instrument. This instrument was used with four angles of (0º,15º,30º, and 45º) and the average value of residual stresses was determined, the value of the residual stress in the original blanks was (10.626 MPa). The X-ray diffraction technology was used to measure the residual stresses. The sheet material used was Aluminum alloy (AL1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The extracted results from the single point incremental forming process were analyzed using analysis of variance (ANOVA) to predict the effect of forming parameters on the residual stresses. The optimum value of the residual stresses (55.024 MPa) was found when using the flat end with round corner tool and radius of (3 mm), wall angle of (55°) and a rotational speed of the tool of (800 rpm). The minimum value of the residual stresses (24.389MPa) was found when using hemispherical tool with diameter of (12 mm), wall angle of (45°) and a rotational speed of the tool of (800 rpm).  

Multiobjective optimization of process variables in single-point incremental forming using grey relational analysis coupled with entropy weights

2021 ◽  
pp. 146442072110204
Author(s):  
Abdulmajeed Dabwan ◽  
Adham E Ragab ◽  
Mohamed A Saleh ◽  
Atef M Ghaleb ◽  
Mohamed Z Ramadan ◽  
...  
Keyword(s):  
Grey Relational Analysis ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Numerical Control ◽  
Single Point Incremental Forming ◽  
Process Variables ◽  
Relational Analysis ◽  
Grey Relational

Incremental sheet forming is a specific group of sheet forming methods that enable the manufacture of complex parts utilizing computer numerical control instead of specialized tools. It is an incredibly adaptable operation that involves minimal usage of sophisticated tools, dies, and forming presses. Besides its main application in the field of rapid prototyping, incremental sheet forming processes can be used for the manufacture of unique parts in small batches. The goal of this study is to broaden the knowledge of the deformation process in single-point incremental forming. This work studies the deformation behavior in single-point incremental forming by experimentally investigating the principal stresses, principal strains, and thinning of single-point incremental forming products. Conical-shaped components are fabricated using AA1050-H14 aluminum alloy at various combinations of fundamental variables. The factorial design is employed to plan the experimental study and analysis of variance is conducted to analyze the results. The grey relational analysis approach coupled with entropy weights is also implemented to identify optimum process variables for single-point incremental forming. The results show that the tool diameter has the greatest effect on the thinning of the SPIF product, followed by the sheet thickness, step size, and feed rate.

Experimental Investigation of Single Point Incremental Forming of Aluminum Sheet in Groove Test

2017 ◽  
Vol 867 ◽  
pp. 177-183 ◽  
Author(s):  
Vikrant Sharma ◽  
Ashish Gohil ◽  
Bharat Modi
Keyword(s):  
Experimental Investigation ◽  
Incremental Forming ◽  
Single Point ◽  
Fractional Factorial ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Backing Plate ◽  
Groove Test ◽  
Factorial Design Of Experiments ◽  
Tool Diameter

Incremental sheet forming is one of the latest processes in sheet metal forming industry which has drawn attention of various researchers. It has shown improved formability compared to stamping process. Single Point Incremental Forming (SPIF) process requires only hemispherical tool and no die is required hence, it is a die-less forming process. In this paper experimental investigation on SPIF for Aluminium sheet has been presented. A groove test on Vertical Machining Centre has been performed. Factors (Step depth, Blank holder clamping area, Backing plate radius, Program strategy, Feed rate and Tool diameter) affecting the process are identified and experiments are carried out using fractional factorial design of experiments. Effect of the factors on fractured depth, forming time and surface finish have been analyzed using Minitab 17 software.

scholarly journals Research on the Influencing Factors of "Scale Veins" of Single Point Incremental Forming Workpieces Surface

2015 ◽  
Vol 9 (1) ◽  
pp. 1025-1032
Author(s):  
Shi Pengtao ◽  
Li Yan ◽  
Yang Mingshun ◽  
Yao Zimeng
Keyword(s):  
Surface Quality ◽  
Incremental Forming ◽  
Single Point ◽  
Spindle Speed ◽  
Experimental Results ◽  
Feed Speed ◽  
Single Point Incremental Forming ◽  
Machining Parameters ◽  
The Mathematical Model

To furthermore optimize the machining parameters and improve the surface quality of the workpieces manufactured by single point incremental forming method, the formation mechanism of the sacle veins on the metal incremental froming workpieces was studied through experiment method. The influence principle of the spindle speed, the feed speed and the material of tip of tools on the length of scale veins was obtained through analyzing the experimental results and building the mathematical model among the length of scale veins were feed speed and spindle speed through measuring the roughness of surfaces and observing the appearance of the forming workpieces. The experimental results showed that, the spindle speed, the feed speed and the material of tool tips have a significant effect on the scale veins formation on the surface of forming workpieces. Therefore, an appropriate group of spindle speed and feed speed can reduce the effect of scale veins on the roughness of single point incremental forming workpieces and furthermore improve the surface quality of forming workpieces.

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