Optimization of Incremental Sheet Metal Forming Parameters by Design of Experiments

The purpose of the paper is to investigate the dependency of various parameters on metal forming process using mathematical models. The incremental sheet metal forming process was studied using Box–Behnken design of experiments along with response from surface methodology analysis. In the study process factors namely feed rate, speed and coolant were analysed to understand the effect on the surface roughness, percentage (%) of thickness reduction, grain size and hardness of the Aluminium (Al) sheet metal, were examined after forming. The surface model analysis predicts that all four responses of the incremental forms show very strong correlation with the experimental results. The optimized process of incremental forming that runs on maintained levels of predicted factors, yield responses very close to that predicted from the model.