Study on Forming Forces of Parts Processed by Single Point Incremental Forming With Dummy Sheet
DOI:
https://doi.org/10.37255/jme.v4i3pp120-128Keywords:
Single point incremental forming, Forming force, Wall Angle, Step size, Dummy sheet, SPIFAbstract
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.
Downloads
References
Kumar S, & Singh, R. (2004) “A low-cost knowledge base system framework for progressive die design” Journal of Materials Processing Technology, Vol: 153, 958-964.
Li, Y., Chen, X., Liu, Z., Sun, J., Li, F., Li, J., & Zhao, G. (2017). “A review on the recent development of incremental sheet-forming process” International Journal of Advanced Manufacturing Technology, Vol. 92(5–8), 2439–2462.
Franzen V, Kwiatkowsk, L, Martins, P. A. F & Tekkaya, A. E. (2009) “Single point incremental forming of PVC” Journal of materials processing technology, Vol:209(1), 462-469.
Martins, P. A. F, Bay, N., Skjødt, M., & Silva M. B (2008),” Theory of single point incremental forming”, CIRP Annals-Manufacturing Technology, Vol:57(1), 247-252.
Silva M B, Skjødt M, Vilaça, ., Bay, N., & Martins, P. A. F. (2009), “Single point incremental forming of tailored blanks produced by friction stir welding”, Journal of Materials Processing Technology, Vol.209(2), 811-820.
Kurra, S., Rahman, N. H., Regalla, S. P., & Gupta, A. K. (2015), “Modeling and optimization of surface roughness in single point incremental forming process” Journal of Materials Research and Technology, Vol:4(3), 304-313.
Beltran, M., Malhotra, R., Nelson, A. J., Bhattacharya, A., Reddy, N. V., & Cao, J. (2013). Experimental study of failure modes and scaling effects in micro-incremental forming. Journal of Micro and Nano-Manufacturing, 1(3), 031005.
Duflou, J. R., Szekeres, A., & Vanherck, P. (2005). Force measurements for single point incremental forming: an experimental study. In Advanced Materials Research (Vol. 6, pp. 441-448). Trans Tech Publications.
Ambrogio, G., Filice, L., & Micari, F. (2006), “A force measuring based strategy for failure prevention in incremental forming”, Journal of materials processing technology, Vol:177(1-3), 413-416.
Duflou, J., Tunckol, Y., Szekeres, A., & Vanherck, P. (2007), “Experimental study on force measurements for single point incremental forming”, Journal of Materials Processing Technology, Vol: 189(1-3), 65-72.
Durante M., Formisano, A., Langella, A., & Minutolo, F. M. C. (2009) “The influence of tool rotation on an incremental forming process” Journal of Materials Processing Technology, Vol: 209(9), 4621-4626.
Petek, A., Kuzman, K., & Kopač, J. (2009), “Deformations and forces analysis of single point incremental sheet metal forming” Archives of Materials science and Engineering, Vol:35(2), 107-116.
Bagudanch, I., Centeno, G., Vallellano, C., & Garcia-Romeu, M. L. (2013),”Forming force in Single Point Incremental Forming under different bending conditions” Procedia Engineering, Vol:63, 354-360.
Bahloul, R., Arfa, H., & Salah, H. B. (2013), “Application of response surface analysis and genetic algorithm for the optimization of single point incremental forming process”, Key Engineering Materials, Vol. 554, 1265-1272
Aerens, R., Eyckens, P., Van Bael, A., & Duflou, J. R. (2010), “Force prediction for single point incremental forming deduced from experimental and FEM observations” The International Journal of Advanced Manufacturing Technology, Vol:46(9-12), 969-982.
Mirnia, M. J., & Mollaei Dariani, B. (2012),” An Upper-Bound Prediction of Tangential Force in Single Point Incremental Forming” Key Engineering Materials, Vol. 504, 833-838
Kumar A & Gulati V. (2018),” Experimental investigations and optimization of forming force in incremental sheet forming” Sādhanā, Vol:43(10), 159.
Koh, K. H., Kang, J. G., & Jung, J. Y. (2016),” The Analysis of Forming Forces in Single Point Incremental Forming” In MATEC Web of Conferences, Vol. 81, 05004.
Li, Y. L., Sun, J., & Li, J. F. (2016), “A Brief Review of Forming Forces in Incremental Sheet Forming” Materials Science Forum Vol. 861, 195-200
Fiorentino, A., Attanasio, A., Marzi, R., Ceretti, E., & Giardini, C. (2011),” On forces, formability and geometrical error in metal incremental sheet forming”, International Journal of Materials and Product Technology, Vol:40(3-4), 277-295.
Skjoedt, M., Bay, N., & Ingarao, B. E. G. (2007),” Single Point Incremental Forming using a Dummy Plate-MultiPlate Forming”, 2nd International Conference on New Forming Technology, Bremen.
Velosa De Sena, J. (2015). Advanced numerical framework to simulate Incremental Forming Processes (Doctoral dissertation, Université de Liège, Liège, Belgique).
Altan, T., & Tekkaya, A. E. (Eds.). (2012). Sheet metal forming: fundamentals. ASM International.
Liu, Z., Li, Y., & Meehan P A (2013),” Experimental investigation of mechanical properties, formability and force measurement for AA7075-O aluminum alloy sheets formed by incremental forming” International Journal of Precision Engineering and Manufacturing, Vol:14(11), 1891-1899.
Young D., & Jeswiet J. (2004)” Wall thickness variations in single-point incremental forming” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol:218(11), 1453-1459.
Salem, E., Shin, J., Nath, M., Banu, M., & Taub, A. I. (2016),” Investigation of thickness variation in single point incremental forming” Procedia Manufacturing, Vol:5, 828-837.
Kivak, T. (2014),” Optimization of surface roughness and flank wear using the Taguchi method in milling of Hadfield steel with PVD and CVD coated inserts” Measurement, Vol:50, 19-28.
Kumar, A., Gulati, V., Kumar, P., & Singh, H. (2019),”Forming force in incremental sheet forming: a comparative analysis of the state of the art” Journal of the Brazilian Society of Mechanical Sciences and Engineering,Vol: 41(6), 251.
Downloads
Published
Issue
Section
How to Cite
