scholarly journals Study of Friction and Wear Effects in Aluminum Parts Manufactured via Single Point Incremental Forming Process Using Petroleum and Vegetable Oil-Based Lubricants

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3973
Author(s):  
José M. Diabb Zavala ◽  
Oscar Martínez-Romero ◽  
Alex Elías-Zúñiga ◽  
Héctor Manuel Leija Gutiérrez ◽  
Alejandro Estrada-de la Vega ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Friction And Wear ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Step Size ◽  
Vertical Step ◽  
Stribeck Curves

This paper focuses on studying how mineral oil, sunflower, soybean, and corn lubricants influence friction and wear effects during the manufacturing of aluminum parts via the single point incremental forming (SPIF) process. To identify how friction, surface roughness, and wear change during the SPIF of aluminum parts, Stribeck curves were plotted as a function of the SPIF process parameters such as vertical step size, wall angle, and tool tip semi-spherical diameter. Furthermore, lubricant effects on the surface of the formed parts are examined by energy dispersive spectroscopy (EDS) and scanning electron microscope (SEM) images, the Alicona optical 3D measurement system, and Fourier-transform infrared spectroscopy (FTIR). Results show that during the SPIF process of the metallic specimens, soybean and corn oils attained the highest friction, along forces, roughness, and wear values. Based on the surface roughness measurements, it can be observed that soybean oil produces the worst surface roughness finish in the direction perpendicular to the tool passes (Ra =1.45 μm) considering a vertical step size of 0.25 mm with a 5 mm tool tip diameter. These findings are confirmed through plotting SPIFed Stribeck curves for the soybean and corn oils that show small hydrodynamic span regime changes for an increasing sample step-size forming process. This article elucidates the effects caused by mineral and vegetable oils on the surface of aluminum parts produced as a function of Single Point Incremental Sheet Forming process parameters.

The Effected of Single Point Incremental Forming Process Parameters on the Formed Part Surface Roughness

2014 ◽  
Vol 979 ◽  
pp. 335-338
Author(s):  
Kittiphat Rattanachan ◽  
Chatchapol Chungchoo
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Process Parameters ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Tool Rotational Speed ◽  
Forming Process ◽  
Inner Surface

The single point incremental forming process (SPIF) are suited for sheet metal prototyping, because it is a low cost production process that produces sheet metal part without any used of die, and easy to adjust the part’s geometry by change toolpath. But the quality of forming parts is still in doubt. In some applications, such as mould cavity for rapid mould and the medical parts, in this case the inside surface roughness plays an importance role. In this paper, the SPIF process parameters that affected to the inner surface roughness were experimental studied. The investigated parameters are composing of tool feed rate, side overlap, depth step and tool radius. The 2k-p factorial experimental design was used to analyze the interaction between each parameter. The results showed that increasing feed rate and depth step decreased inner surface roughness. Reducing tool rotational speed and feed rate reduced inner surface roughness. So increasing depth step with decreasing side overlap reduced inner surface roughness. The large tool radius and lower side overlap improved inner surface roughness. The large tool radius and higher depth step improved inner surface roughness. And last, reducing tool rotational speed with larger tool radius, the inner surface roughness is decreased.

Force Measurements for Single Point Incremental Forming: An Experimental Study

2005 ◽  
Vol 6-8 ◽  
pp. 441-448 ◽  
Author(s):  
Joost R. Duflou ◽  
Alexander Szekeres ◽  
P. Vanherck
Keyword(s):  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Force Measurements ◽  
Test Program ◽  
Forming Process ◽  
Step Size ◽  
Experimental Platform ◽  
Vertical Step ◽  
The Relationship

In this paper an experimental platform capable of measuring forces in process during an incremental forming procedure is described and the results garnered from it are presented. Some of the earliest measurements of forces in incremental forming and the changes induced on the measured load are reported. Using a table type force dynamometer with incremental forming fixture mounted on top, three components of force were measured throughout the forming process. They were found to vary as the parts were made. The reported experimental test program was focused on the influence of three different process parameters on the forming forces: the vertical step size between consecutive contours, the diameter of the tool and the steepness of the part’s wall. For the tested material, analytical results demonstrating the relationship between the respective process parameters and the induced forces are presented in this paper.

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>

Parameter optimization and texture evolution in single point incremental sheet forming process

2019 ◽  
Vol 234 (1-2) ◽  
pp. 126-139 ◽  
Author(s):  
Shamik Basak ◽  
K Sajun Prasad ◽  
Amarjeet Mehto ◽  
Joy Bagchi ◽  
Y Shiva Ganesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Regression Models ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Input Process ◽  
Truncated Cone

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.

scholarly journals ANÁLISE EXPERIMENTAL DE ESTAMPABILIDADE DA CHAPA DE AÇO ASTM A653 DURANTE O PROCESSO DE ESTAMPAGEM INCREMENTAL POR PONTO ÚNICO E AVALIAÇÃO DA RUGOSIDADE IMPRESSA NA SUPERFÍCIE CONFORMADA

2021 ◽  
Vol 9 (209) ◽  
pp. 1-51
Author(s):  
Cleiton Ferreira
Keyword(s):  
Incremental Forming ◽  
True Strain ◽  
Single Point ◽  
Roughness Parameter ◽  
Incremental Sheet Forming ◽  
Surface Finishing ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Vertical Step ◽  
Incremental Step

This study aims to evaluate the behavior of ASTM A653 CS-A G90 steel in the process of Incremental Sheet Forming – ISF, based on the following parameters: diameter of the tool (Dt in mm) and the vertical step size between consecutive contours (∆z in mm). The experiments were based on a variation of the ISF process, called Single Point Incremental Forming - SPIF. In this study, seventeen tests were conducted using a punching tool with diameters (Dt ) of 5, 6 and 8 mm and vertical steps (∆z) of 0.4, 0.6 and 0.8 mm, intending to evaluate the true strain to the ISF process and the surface finishing measured by roughness parameter (Rz). Whereas, for the execution of practical testing, the resources used were a CNCmachining center with three axes, tools for incremental forming and a sheet-press device. As a result, greater depths were achieved using an incremental step of 0.4 mm. In additional tests, it came to attention that the diameter of the tool was also an important parameter when it is desired to increase the formability and greater depths are obtained when using small diameters. It can be observed yet, there is a tendency to increase the roughness parameter Rz when using greater vertical steps ∆z

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.

Single Point Incremental Forming Springback Reduction Using Edge Stiffener

2020 ◽  
Author(s):  
Tyler J. Grimm ◽  
Gowtham V. Parvathy ◽  
Laine Mears
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Back Side ◽  
Forming Process ◽  
Step Size ◽  
Elastic Deformations ◽  
Form Complex ◽  
Large Step ◽  
Large Step Size

Abstract Single point incremental forming (SPIF) is a dieless forming process which uses local deformations to form complex geometries. This is achieved through the use of a typically hemispherical tipped forming tool. Several variations of SPIF have been developed to improve the performance of this process. This includes the use of a partial die which is placed on the back-side of the material. The forming tool is then able to press the material into this partial die. Another method is to utilize a clamping fixture with a periphery that closely matches that of the desired geometry. While both of these methods improve the performance of SPIF, they also require dedicated fixturing. While these modifications still present an advantage over traditional stamping, it is desirable to avoid the use of any geometry-specific equipment. Springback is a significant issue when performing traditional SPIF. Springback can occur in two different ways: local and global. Local springback results from the elastic deformations created outside the region located directly beneath the forming tool. This causes poor accuracy as a result. Compensation methods have been developed to overcome this type of springback but are faced with certain limitations. Global springback refers to the springback experienced once the material is removed from its clamping fixture. This springback is a result of all residual stresses produced during forming. This springback is much more difficult to reduce and often requires annealing the workpiece subsequent to forming. A toolpath approach is explored herein as a method to reduce springback without the use of geometry-specific equipment. The toolpath developed begins at the edge of the clamping fixture, regardless of the geometry shape, and forms the flashing material prior to the desired geometry. By starting the toolpath along the edge of the fixture, elastic deformations are minimized. Additionally, the work hardening produced during this forming acts as a stiffener for the desired geometry, which behaves as a frame which matches the periphery of the desired geometry. This method was experimentally tested for its accuracy improvements when forming a truncated pyramid from 5052 aluminum. The angle of this stiffener, the step size of the stiffener, and the size of the desired geometry were varied. The fixture dimensions were held constant. This method was found to reduce the overall springback of the part and increase the accuracy of the resulting geometry. Furthermore, it was found that a large step size can be used to form the stiffener section of the part. By using a large step size, the time it takes to form this sacrificial region is minimized.

The Effect of Lubricants and Material Properties in Surface Roughness and Formability for Single Point Incremental Forming Process

2014 ◽  
Vol 979 ◽  
pp. 359-362
Author(s):  
Nuttaphong Sornsuwit ◽  
Sunthorn Sittisakuljaroen
Keyword(s):  
Surface Roughness ◽  
Adhesive Wear ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Sheet Surface ◽  
Air Blowing ◽  
Asymmetric Shape ◽  
High Roughness

The single point incremental forming (SPIF) is a manufacturing process which allows small batch and asymmetric shape fabrication. The research focuses on its applications by consider surface roughness and formability. The surface roughness of specimen was resulted by the influence obtained between tool and specimen, where the lubricant played a significant role during the forming process, as well as material elongation as a mechanical property governed the formability of metal sheet. Surface roughness tester, SEM, EDS and profilometer were used for the characterizations. The results showed that low roughness value (Ra) of SUS 304 and SUS 316L obtained by applying air blowing as a lubricant, while Ti Gr2 could obtain low roughness by using MoS2. The behavior of wear was an adhesive wear which transfer to an abrasive wear. SUS 304 and SUS 316L sheet of test specimens achieved higher depth in forming by air lubricant and MoS2, and Ti Gr2 sheet revealed a better formability with MoS2. Furthermore, the highest depth was correlated with high roughness value for each material.

Incrementally Formed Stiffeners Effect on the Reduction of Springback in 2024-T3 Aluminum After Single Point Incremental Forming

2015 ◽  
Author(s):  
Brandt J. Ruszkiewicz ◽  
Sean S. Dodds ◽  
Zachary C. Reese ◽  
John T. Roth ◽  
Ihab Ragai
Keyword(s):  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Stress Concentrations ◽  
Forming Process ◽  
Step Size ◽  
New Process ◽  
Geomagic Software ◽  
Truncated Pyramid ◽  
The Ideal

Single Point Incremental Forming (SPIF) is a relatively new process to form sheet metal. SPIF utilizes machines such as CNC’s and mills to form a part by making several spiraled passes, deforming the metal a certain distance, known as the step-size, with each pass. One major issue with this process is global springback. Once the metal is removed from its clamping fixture, the residual stresses that resulted from the forming process cause the material to springback. The purpose of this paper is to demonstrate how incrementally forming a stiffener on the outside of the desired geometry will manipulate the stress concentrations in the metal, and effectively reduce the amount of global springback that occurs after the specimen is unclamped from its fixture. For these tests, stiffeners were formed on the outside of a truncated pyramid; the material used for these test was 2024-T3 aluminum. After the work pieces were removed from their clamping fixtures, the amount of springback that they experienced was examined using Geomagic software to determine the ideal stiffener parameters for reducing global springback for a truncated pyramid in 2024-T3 aluminum.

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