Analysis of Incremental Sheet Forming of Aluminum Alloy

Abstract

Recent developments in incremental sheet forming have resulted in the creation of novel manufacturing processes that are highly adaptable and could bring significant economic benefits for advanced technologies and low-volume production. In this manuscript, the following variables were examined: the variation in the deformation forces for a part with a pyramidal trunk shape; the variation in the deformations and thinning of the Al 3003 material during the incremental forming process; and the variation in the accuracy of the incrementally formed part and the quality of the surfaces (surface roughness). The components of the forces in the incremental forming have increasing values from the beginning of the process to the maximum value due to the hardening process. The TiN-coated tool ensures lower values of the forming components. Due to the kinematics of the forming process, deviations, especially in shape, from the part in the drawing are observed, which are shown by the radius of curvature of the side wall of the part, the appearance of a radius of connection between the wall and the bottom of the part, as well as dimensional deviations that are expressed by the variation in the forming depth. Concerning the smoothness of the surfaces, it was observed that the best roughness results were obtained in the case of the TiN-coated tool.

Improved Surface Quality with TiN‐Coated Tool

“…In both instances, the utilized tools possessed a ball with a diameter measuring Ø 12 mm, with (53–58) HRC hardness. [ 7 ] The TiN layer has a measured hardness of ≈2300 HV, while the coating thickness ranges from 2 to 4 µm.…”

“…The only studies are those carried out by the researchers of the present research, who identified a significant improvement of the surface characteristics with the deposition of TiN layer. [ 7 ]…”

Influence of Technological Parameters on Machining Accuracy in Incremental Forming

“…One additional factor contributing to deviations is the utilisation of robotic systems, as opposed to milling computer numerical control (CNC) machines. As stated in references [23,45], the employment of robots might result in positional inaccuracies of the tool centre due to the elastic deformations experienced by the robot during the machining process.…”

“…These deviations, in turn, give rise to faults in the geometric properties of the produced components. One crucial measure to address in the resolution of this issue involves incorporating appropriate compensation for the anticipated deflection in the tool path, [23,24]. The accurate estimation of the maximal forming force of the SPIF and comprehending the impact of the input parameters on this force is of utmost importance.…”

Investigating the Impact of Process Parameters on Thinning and Formability in Aluminum Alloy AA 1050 Incremental Sheet Metal Forming

“…The authors optimized the tool path, speed, and step down by using a Taguchi method that considered many criteria at once. Coman and Mazurchevici [15] analyzed the context of an incremental sheet metal forming process. This study investigated how the thining of aluminum was affected by the presence of various parameters.…”