An analysis of the effect of various parameters on surface roughness, springback and thinning while performing single point incremental forming on polypropylene sheet

Abstract

One of the sheet metal forming processes known as single point incremental forming (SPIF) uses simple tools instead of devoted costly dies and gives us the flexibility to incorporate the change in the design of the product by using the same tools. Polymers are increasingly used nowadays because of the higher strength to weight ratio. Polymers can be deformed in the required shape using SPIF. The effect of SPIF on polypropylene is studied experimentally in the current work. Springback, thinning and surface roughness are the responses studied while performing SPIF at room temperature. Tool diameter, wall-angle, step size and feed rate are the factors considered for the present study. The effect of the tool diameter was found to be significant in each of the responses considered. The increase in tool diameter causes an increase in the springback and surface roughness. The percentage of thinning and surface roughness was found to be increasing with the increase in wall angle. With the increase in wall angle, the percentage springback is found to be decreasing.

Minimizing the Main Strains and Thickness Reduction in the Single Point Incremental Forming Process of Polyamide and High-Density Polyethylene Sheets

“…The influence of the process parameters, whether they are parameters related to the processed part or parameters related to the forming technology, has also been studied. For instance, the influence of the input parameters on the surface roughness, springback and thinning has been analyzed for polypropylene [ 36 ] and polyvinylchloride sheets [ 37 ]. Kharche and Barve used the Taguchi method to investigate the influence of the rotational speed, feed rate, step down and wall angle on the accuracy of parts manufactured by SPIF and made of polyamide 6, with direct reference to the final thickness, final depth of the part and wall angle deviation [ 38 ].…”

Shape Accuracy in Single Point Incremental Forming of Conical Frustums from Titanium CP2 Sheets

“…It was found that the wall angle is the most influential parameter on the springback amount. Jain et al (2021) investigated the effect of various parameters on springback and thinning while performing SPIF on polypropylene sheets. The springback was found to increase with increasing tool diameter.…”