Effect of Tool Shape on Surface Finish of Components Formed Through Incremental Sheet Forming Process

Abstract

This work explores the effect of tool geometry on surface finish in incremental sheet forming (ISF) process. In the present work, two different tool geometries i.e. hemispherical shaped tool and ellipsoidal shaped tool are considered. Area at tool-sheet contact and scallop height were calculated for both the tool geometries. To assess the effect of tool geometry on the surface finish of the formed components, both analytical and experimental approaches have been used. A test geometry having the shape of frustum of pyramid was considered for the proposed investigation and four surface roughness parameters i.e. arithmetic mean surface roughness (Ra), root mean square surface roughness (Rq), maximum peak-to-valley height (Rt) and average peak-to-valley height (Rz) have been selected as response parameters. Based on the analytical model and experimental investigations, both qualitative and quantitative comparisons had been made among the effects of hemispherical and ellipsoidal tool geometries on surface finish. The investigation deduces that better surface finish of the formed component can be achieved by using ellipsoidal shaped tool rather than the hemispherical shaped tool.

Parameter optimization and texture evolution in single point incremental sheet forming process

“…Post-deformation studies such as microhardness and surface roughness offer a reliable inspection tool to detect the quality of the deformed component. 23–27 During SPIF process, the incremental steps lead to progressive changes in plastic flow across the component, which can accumulate risk of unsatisfactory performance during the application. For this reason, microhardness and surface roughness profile analysis at different locations of SPIF truncated cone are essential.…”

Numerical analysis of the effects of ultrasonic vibrations and elevated temperature in incremental sheet forming

“…Sheet thickness, tool diameter, incremental depth and wall angle are the main influencing parameters, which affect the response parameters including forming forces. 1,2 The influence of the tool diameter on the formability and surface roughness of the part formed has been explained by Bhattacharya et al 3 The effect of tool shape on the surface finish of components formed by the ISF had been analysed by Kumar et al 4 Apart from the influence of the process parameters, several researchers contributed to understanding the deformation and fracture mechanics of ISF. [5][6][7] Bouhamed et al 8 studied the damage behaviour and springback during the ISF process.…”