Effect of the Single-Point Incremental Forming Process Parameters on the Surface Roughness of Aluminum Alloy Al 2024-O Draw Pieces

Abstract

The incremental sheet metal forming process is a highly adaptable manufacturing process for producing threedimensional products without the need for specialized tool typically required in traditional forming processes. This innovative process finds extensive applications in various industries, including aerospace, automobile, and other industrial applications. This study explores the application of the single-point incremental forming (SPIF) process to manufacture truncated pyramids while investigating the impact of specific process parameters on surface roughness. In this study, three parameters wall angle, sheet thickness, and step depth were examined, each at three different levels. A full factorial design (L27) was used to design the experimental work and statistical analysis utilizing Analysis of Variance (ANOVA) was utilized to analyze the collected data and predict the impact of single-point incremental forming process parameters on surface roughness. The tool geometry was a hemispherical end tool with a diameter of (8 mm) and the sheet material was aluminum alloy (Al 2024-O). The computer numerical control (CNC) milling machine was used to move the tool. The optimal average roughness (Ra) value was achieved with a wall angle of 60°, a sheet thickness of 2 mm, and a step depth of 0.2 mm.

Experimental investigation and numerical optimization of sheet metal forming limits during deep drawing process of DD14 steel

“…10). It emerges from the analysis of this FLC curve that the limit points of strains (36, 3, 16, 2c and 7c) are those of the squares located at the deep drawn part bottom corners (2c and 7c) or at the edge of that (36,16). In return, the majority of the squares were located in the uniaxial traction zone and some of them (25, 40, 32 and 33) located in the deep drawn part wall were deformed in the wrinkle form.…”

“…Hamza et al [15] studied by numerical simulation the deep drawing parameter's effect on the plastic strain evolution in the metal sheet during the forming operation. Habeeb et al [16] studied how the Single-Point incremental forming process parameters impact the blank surface roughness. Rabia et al [17] investigated how PVD coatings, lubrication conditions, and operating parameters impact tribological behavior, forming forces, and energy consumption when deep drawing is performed.…”

Experimental Investigation of Load-Bearing Capacity in EN AW-2024-T3 Aluminum Alloy Sheets Strengthened by SPIF-Fabricated Stiffening Rib

“…The study was also supported by ANN modeling. Habeeb et al [24] examined the effect of step depth, sheet thickness, and wall angle influences on the surface roughness of stiffening ribs fabricated by SPIF in Al 2024-O draw pieces of an aluminum alloy by applying an analysis of variance (ANOVA) based on a full factorial design. Ján Slota et al [25] examined local buckling in an aluminum alloy, which was stretched by the SPIF process.…”