An Investigation Study of Tool Geometry in Single Point Incremental Forming (SPIF) and their effect on Residual Stresses Using ANOVA Model

Abstract

Incremental forming is a flexible sheet metal forming process which is performed by utilizing simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. This work presents the single point incremental forming process for producing pyramid geometry and studies the effect of tool geometry, tool diameter, and spindle speed on the residual stresses. The residual stresses were measured by ORIONRKS 6000 test measuring instrument. This instrument was used with four angles of (0º,15º,30º, and 45º) and the average value of residual stresses was determined, the value of the residual stress in the original blanks was (10.626 MPa). The X-ray diffraction technology was used to measure the residual stresses. The sheet material used was Aluminum alloy (AL1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The extracted results from the single point incremental forming process were analyzed using analysis of variance (ANOVA) to predict the effect of forming parameters on the residual stresses. The optimum value of the residual stresses (55.024 MPa) was found when using the flat end with round corner tool and radius of (3 mm), wall angle of (55°) and a rotational speed of the tool of (800 rpm). The minimum value of the residual stresses (24.389MPa) was found when using hemispherical tool with diameter of (12 mm), wall angle of (45°) and a rotational speed of the tool of (800 rpm).

Fabrication and Analysis of Denture Plate Using Single Point Incremental Sheet Forming

“…as shown in figure 7. The forming fixture frame was built and designed by [26] and is mounted on the CNC machine to fix the sheet during the manufacturing process. The Initial blank dimensions were 225mm×225mm, and a thickness of 0.5 and 0.8 for 304 and 316L, respectively.…”

Optimizing the five magnetic abrasive finishing factors on surface quality using Taguchi-based grey relational analysis

“…Regression's primary goal is to identify the operational parameter that most significantly affects performance measures. When the proportion of contribution is higher, it indicates that the element has a greater influence on the features of the output [54][55][56].…”