scholarly journals Split-Plot I-Optimal Design Optimisation of Combined Oil-Based and Friction Stir Rotation-Assisted Heating in SPIF of Ti-6Al-4V Titanium Alloy Sheet under Variable Oil Pressure

Metals ◽  
2022 ◽  
Vol 12 (1) ◽  
pp. 113
Author(s):  
Tomasz Trzepieciński ◽  
Marcin Szpunar ◽  
Robert Ostrowski
Keyword(s):  
Titanium Alloy ◽  
Optimal Design ◽  
Feed Rate ◽  
Rotational Speed ◽  
Tool Rotational Speed ◽  
Step Size ◽  
Wall Angle ◽  
Split Plot ◽  
Input Parameters ◽  
Tungsten Carbide Tool

The aim of this paper is to determine the optimal input parameters for the process in order to ensure the maximum formable wall angle is obtained in a conical frustum with a varying wall angle fabricated using Single Point Incremental Forming (SPIF). The test material was 0.8-mm-thick Ti-6Al-4V titanium alloy sheets, and the test used a tungsten carbide tool with a rounded tip with a radius of 4 mm. Complete workpieces were heated using hot oil with a temperature of about 200 °C, and in addition, the high rotation speed of the forming tool generated an amount of friction heat. The input parameters were tool rotational speed, feed rate, step size, and tool rotation direction. Various oil pressures were used to improve both the accuracy of the components formed and the friction heating process. On the basis of calculations performed by means of the response surface methodology, split-plot I-optimal design responses were obtained by means of polynomial regression models. Models were fitted using REstricted Maximum Likelihood (REML), and p-values are derived using the Kenward–Roger approximation. Observation of the fracture surface of Ti-6Al-4V drawpieces showed that the destruction is as a result of ductile fracture mode. Tool rotational speed and step size are the most significant factors that affect the axial force, followed by feed rate. It was also found that step size is the most significant factor that affects the in-plane SPIF force.

The Effect of Minimal Quantity Lubrication (MQL) on the Surface Roughness of Titanium Alloy Ti-6Al-4V ELI in Turning Process

2010 ◽  
Vol 146-147 ◽  
pp. 1750-1753 ◽  
Author(s):  
C.H. Che Haron ◽  
J.A. Ghani ◽  
Mohd Ali Sulaiman ◽  
L.R. Intan ◽  
M.S. Kasim
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Optimum Condition ◽  
Feed Rate ◽  
Influence Factor ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Minimum Quantity Lubricant ◽  
Minimal Quantity Lubrication ◽  
Tungsten Carbide Tool

This paper investigates the effect of minimum quantity lubricant (MQL) on the surface roughness of titanium alloy Ti-6Al-4V ELI when turning using uncoated tungsten carbide tool. The response surface method (RSM) design of experiment using Box-behnken was used to accomodate the turning experiment factors and levels. Turning parameters studied were cutting speed (100, 135, 170 m/min), feed rate (0.15, 0.2, 0.25 mm/rev) and depth of cut (0.6, 0.8, 1.0 mm). The results show that the feed rate was the most influence factor controlling the surface roughness produced. The feed rate (F) was found directly proportional with the surface roughness value (Ra) but inversely proportional to the cutting speed (Vc). MINITAB software was used to develop a surface roughness model, and the optimum condition was at 160 m/min of cutting speed, 0.18 mm/rev of feed rate and 1 mm of depth of cut. At the optimum condition low value of 1.54 μm surface roughness was obtained.

scholarly journals Modelling and Analysis of Surface Evolution on Turning of Hard-to-Cut CLARM 30NiCrMoV14 Steel Alloy

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1751
Author(s):  
Syed Muhammad Raza ◽  
Aqib Mashood Khan ◽  
Muhammad Umar Farooq ◽  
Asif Iqbal ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Mathematical Modelling ◽  
Surface Finish ◽  
Feed Rate ◽  
Rotational Speed ◽  
Prediction Models ◽  
Pressure Vessels ◽  
Depth Of Cut ◽  
Central Component ◽  
Steel Alloy ◽  
Input Parameters

Industrial practitioners are working on predictive solutions for the precise evaluation of input parameters and processed surfaces of engineering materials. To aid the aeronautical industry, this study is an effort to develop the mathematical modelling for comprehensive surface analysis of input parameters and surface finish after dry machining of CLARM HBR, a steel alloy with attractive mechanical properties and wide applications in large caliber gun barrels and high-pressure vessels. Feed rate, rotational speed, and depth of cut were taken as quantitative parameters, whereas machining time was considered as a categorical factor with a classification of three levels. Response surface methodology (RSM) with a central component design has been used for the constitution of the experimental design, mathematical modelling, and analysis of developed models. Eighteen samples were prepared to perform the experimentation for the development of prediction models. The adequacy of the developed models was verified using analysis of variance (ANOVA), and the models were validated using confirmatory trial experiments, which revealed the experimental results agreeing with predictions. The feed rate was the most significant parameter in achieving the desired surface finish. An increase in rotational speed at a low feed rate resulted in very fine surface texture, as though it deteriorated the surface finish at higher feed rates. The superior surface quality obtained was 0.137 μm at parametric settings of 0.19 mm/rev feed, 90 rpm speed, 3 mm depth of cut, and 4 min time. Overall, higher values of surface roughness were frecorded in the third level of process variable time. The developed empirical models are expected to aid manufacturers and machining practitioners in the prediction of the desired surface finish concerning different parameters before the experimentations.

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.

scholarly journals Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1640
Author(s):  
Tomasz Trzepieciński ◽  
Andrzej Kubit ◽  
Andrzej Dzierwa ◽  
Bogdan Krasowski ◽  
Wojciech Jurczak
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Rotational Speed ◽  
Single Point ◽  
Core Material ◽  
Tool Rotational Speed ◽  
Roughness Parameters ◽  
Step Size ◽  
Vertical Step

The article presents the results of the analysis of the interactions between the single point incremental forming (SPIF) process parameters and the main roughness parameters of stiffened ribs fabricated in Alclad aluminium alloy panels. EN AW-7075-T6 and EN AW-2024-T3 Alclad aluminium alloy sheets were used as the research material. Panels with longitudinal ribs were produced with different values of incremental vertical step size and tool rotational speed. Alclad is formed of high-purity aluminium surface layers metallurgically bonded to aluminium alloy core material. The quality of the surface roughness and unbroken Alclad are key problems in SPIF of Alclad sheets destined for aerospace applications. The interactions between the SPIF process parameters and the main roughness parameters of the stiffened ribs were determined. The influence of forming parameters on average roughness Sa and the 10-point peak–valley surface roughness Sz was determined using artificial neural networks. The greater the value of the incremental vertical step size, the more prominent the ridges found in the inner surface of stiffened ribs, especially in the case of both Alclad aluminium alloy sheets. The predictive models of ANNs for the Sa and the Sz were characterised by performance measures with R2 values lying between 0.657 and 0.979. A different character of change in surface roughness was found for sheets covered with and not covered with a soft layer of technically pure aluminium. In the case of Alclad sheets, increasing the value of the incremental vertical step size increases the value of the surface roughness parameters Sa and Sz. In the case of the sheets not covered by Alclad, reduction of the tool rotational speed increases the Sz parameter and decreases the Sa parameter. An obvious increase in the Sz parameter was observed with an increase in the incremental vertical step size.

Impact of Tool Pin Geometry and Optimized Process Parameters on Mechanical Properties of Friction Stir Welded AZ80A Mg Alloy

2016 ◽  
Vol 866 ◽  
pp. 151-155 ◽  
Author(s):  
V. Jaiganesh ◽  
P.K. Nagarajan ◽  
P. Sevvel ◽  
J. Dhileep Kumar ◽  
S. Manivannan
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Feed Rate ◽  
Rotational Speed ◽  
Mg Alloy ◽  
Tool Rotational Speed ◽  
Pin Geometry ◽  
Az80a Mg Alloy ◽  
Parameter Values ◽  
Tool Pin

In this paper, the influence of optimized FSW process parameters namely tool rotational speed, feed rate, mechanical axial force and impact of tool pin geometry on the mechanical properties of AZ80A Mg alloy are experimentally investigated in a detailed manner. M35 grade High Speed Steel (HSS) tool with three different pin geometries namely straight cylindrical, threaded cylindrical and taper cylindrical was employed in this investigation. The joints obtained under these conditions are subjected to tensile tests as per ASTM (American Society for Testing and Materials) B557M – 10 standards and tensile fracture surfaces are examined using optical and Scanning Electron Microscope (SEM). The investigations proved that defect free sound joints with better mechanical properties are produced by taper cylindrical tool pin geometry under optimized process parameter values. It was experimentally found that the optimized FSW process parameter values namely 1.0 mm/min feed rate, 5 kN axial force, 1000 rpm of tool rotational speed along with a taper cylindrical pin profiled tool is preferable for FSW of AZ80A Mg alloy of 5mm thickness.Moreover, this experimental work revealed us that the taper cylindrical pin profiled tool fabricated sound, defect free welded joints along with better & improved mechanical properties when compared with other two pin profiles.

Multi-objective optimization in incremental sheet forming of Ti-6Al-4V alloy using grey relational analysis method

2021 ◽  
pp. 095440892110637
Author(s):  
C Veera Ajay ◽  
S Elangovan ◽  
S Pratheesh Kumar ◽  
K Manisekar
Keyword(s):  
Grey Relational Analysis ◽  
Feed Rate ◽  
Rotational Speed ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Analysis Method ◽  
Multi Objective Optimization ◽  
Tool Rotational Speed ◽  
Relational Analysis ◽  
Grey Relational

Incremental sheet forming is a novel approach and advanced manufacturing process in industries, where it is capable of producing complex geometrical components with high accuracy. In this study, Ti-6Al-4V material used in aircraft, naval ships, spacecraft, armour plating and missiles was considered to determine the formability in the incremental sheet forming process. A 20 set of experiments were conducted considering three process variables such as tool rotational speed, step depth and feed rate on the response variables such as formed wall thickness, surface roughness, thrust force and wall angle. The process parameters are optimized using the grey relational analysis method to achieve a better quality of products. By execution multi-objective optimization using grey relational analysis, it is observed that 200 r/min tool rotational speed, 0.1 mm step depth and 2000 mm/min feed rate are optimum parameter settings.

Effect of Incremental Forming Process Parameters on Aluminum Alloy Using Experimental Studies

2015 ◽  
Vol 1119 ◽  
pp. 633-639 ◽  
Author(s):  
Sunil D. Majagi ◽  
G. Chandramohan ◽  
Mouleeswaran Senthil Kumar
Keyword(s):  
Aluminium Alloy ◽  
Process Parameters ◽  
Feed Rate ◽  
Rotational Speed ◽  
Incremental Sheet Forming ◽  
Thickness Reduction ◽  
Tool Rotational Speed ◽  
Forming Process ◽  
Vertical Step ◽  
Tool Diameter

Incremental Sheet Forming (ISF) process is Innovative and cost effective technology trend for forming products in manufacturing industries. The current research is to study and investigate the influence of incremental sheet forming process parameters on response surfaces of aluminium alloy sheet components. In this experiment, Aluminium alloy AA1050 sheet was selected to process forming by using CNC machining centre without expensive dies. Individual and interactive effect of different factors such as, thickness of sheet, tool diameter, vertical step, feed rate, and tool rotational speed at different levels were assessed to improve the processing time. For the design of experiment (DOE), Taguchi’s L27 orthogonal array was used to investigate and optimize the influencing ISF process parameters. From ANOVA results, it was found that for thickness reduction, the influencing factors were as following; feed rate (21.40 %); for roughness, tool rotation speed (20.43 %) and for hardness, thicknesses of sheet (39.49 %). Response Surface Methodology (RSM) showed that optimal values obtained were 0.46 mm, 10 mm, 0.6818 mm, 2232.32 mm/min., and 2626 rpm for thickness of sheet, tool diameter, vertical step, feed rate and tool rotational speed respectively. For percentage thickness reduction of 59.6%, minimum roughness 2.09μm, and maximum hardness 41.7 BHN, the confirmatory test showed values of 64.78 % thickness reduction, roughness of 2.14μm and hardness of 44.82 BHN that were in agreement with the predicted value.

Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

2020 ◽  
Vol 38 (8A) ◽  
pp. 1137-1142
Author(s):  
Baqer A. Ahmed ◽  
Saad K. Shather ◽  
Wisam K. Hamdan
Keyword(s):  
Vickers Hardness ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Step Size ◽  
Coil Current ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

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