Effects of Forming Tools and Process Parameters on Surface Roughness in Incremental Sheet Forming, a Review

Khalil, Umair; Aziz, Haris; Jahanzaib, Mirza; Wasim, Ahmad; Hussain, Salman; Hafeez, Faisal

doi:10.12913/22998624/90223

Cited by 4 publications

(3 citation statements)

References 54 publications

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“…Appropriate selection of the parameters of the sheet metal forming process using single point incremental forming (SPIF) is intended to ensure appropriate surface quality in terms of roughness and, at the same time, an economically justified forming time [ 1 , 2 ]. The basic parameters in the process are: tool rotational speed, feed rate, step size, size and shape of the tool, type of sheet metal, and tool path [ 3 , 4 , 5 ].…”

Section: Introductionmentioning

confidence: 99%

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

et al. 2021

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The article presents the results of the analysis of the interactions between the single point incremental forming (SPIF) process parameters and the main roughness parameters of stiffened ribs fabricated in Alclad aluminium alloy panels. EN AW-7075-T6 and EN AW-2024-T3 Alclad aluminium alloy sheets were used as the research material. Panels with longitudinal ribs were produced with different values of incremental vertical step size and tool rotational speed. Alclad is formed of high-purity aluminium surface layers metallurgically bonded to aluminium alloy core material. The quality of the surface roughness and unbroken Alclad are key problems in SPIF of Alclad sheets destined for aerospace applications. The interactions between the SPIF process parameters and the main roughness parameters of the stiffened ribs were determined. The influence of forming parameters on average roughness Sa and the 10-point peak–valley surface roughness Sz was determined using artificial neural networks. The greater the value of the incremental vertical step size, the more prominent the ridges found in the inner surface of stiffened ribs, especially in the case of both Alclad aluminium alloy sheets. The predictive models of ANNs for the Sa and the Sz were characterised by performance measures with R2 values lying between 0.657 and 0.979. A different character of change in surface roughness was found for sheets covered with and not covered with a soft layer of technically pure aluminium. In the case of Alclad sheets, increasing the value of the incremental vertical step size increases the value of the surface roughness parameters Sa and Sz. In the case of the sheets not covered by Alclad, reduction of the tool rotational speed increases the Sz parameter and decreases the Sa parameter. An obvious increase in the Sz parameter was observed with an increase in the incremental vertical step size.

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Section: Introductionmentioning

confidence: 99%

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

et al. 2021

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“…This is due to the specificity of the SPIF method used, consisting in gradual deformations of the sheet metal due to local stretching of the material with a pin tool following a tool path controlled by a milling machine. The incremental sheet forming technology is a forming technology classified to the rapid prototyping methods which consist in a gradual adding of the material, layer-by-layer, until the desired form is created [8]. In this case of SPIFs methods, the inner surface of the drawpiece consists in linear cyclic grooves (Fig.…”

Section: Resultsmentioning

confidence: 99%

Application of X-ray Diffraction for Residual Stress Analysis in Truncated Cones Made by Incremental Forming

Krasowski¹,

Kubit²,

Trzepieciński³

et al. 2020

Adv. Sci. Technol. Res. J.

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The final accuracy of the parts formed using single point incremental forming greatly depends on the mechanical properties of the material to be formed and the residual stress formation. In this paper, an X-ray diffraction technique was used to study the distribution of the residual stress along the generating line of the conical drawpiece. A DC04 steel sheet with a thickness of 0.8 mm was used as a test material. The basic mechanical properties of the DC04 sheet metal were determined in the uniaxial tensile test according to the EN ISO 6892-1:2016. It was found that the maximum amount of the residual stress existed in a point located in the midway between a base and a truncation of the drawpiece. In the outer surface of the drawpiece, the orange peel defect associated with a rough surface appearance after SPIF a drawpiece, was observed. In contrast, the inner surface of component was characterized by linear grooves associated with the interaction of tool tip with the sheet surface. This defect is mainly influenced by vertical step size.

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“…Because forming tools are not available in markets as a part of an assortment made, thus a used tool, which usually is a hemispherical tool, was designed and manufactured by researchers. A review article pointed out the effect of forming tools and other process parameters on surface roughness in ISF [14]. They observed 89 publications from 2000-2005, 457 from 2005-2010, 1490 from 2010-2015, and 829 from 2015-2017.…”

Section: Introductionmentioning

confidence: 99%

Predict the Effects of Forming Tool Characteristics on Surface Roughness of Aluminum Foil Components Formed by SPIF Using ANN and SVR

Najm

Paniti

2020

Int. J. Precis. Eng. Manuf.

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In the present work, multiple forming tests were conducted under different forming conditions by Single Point Incremental Forming (SPIF). In which surface roughness, arithmetical mean roughness (Ra) and the ten-point mean roughness (Rz) of AlMn1Mg1 sheet were experimentally measured. Also, an Artificial Neural Network (ANN) was used to predict the (Ra) and (Rz) by adopting the data collected from 108 components that were formed by SPIF. Forming tool characteristics played a key role in all the predictions and their effect on the final product surface roughness. In the aim to explore the proper materials and geometry of forming tools, different ANN structures, different training, and transfer functions have been applied to predict (Ra) and (Rz) as an output argument. Furthermore, Support Vector Regression (SVR) with different kernel types have been used for prediction, together with Gradient Boosting regression to sort the effective parameters on the surface roughness. The input arguments were tool materials, tool shape, tool end/corner radius, and tool surface roughness (Ra and Rz). The actual data subjected to a fit regression model to generate prediction equations of Ra and Rz. The results showed that ANN with one output gives the best R-Square (R2). Levenberg-Marquardt backpropagation (Trainlm) training function recorded the highest value of R2, 0.9628 for prediction Ra using Softmax transfer function whereas 0.9972 for Rz by Log- Sigmoid transfer function. Furthermore, tool materials, together with tool surface (Ra), are playing a significant importance role, affecting the sheet surface roughness (Ra). Whereas tool roughness Rz was the critical parameter effected on the Rz of the product. Also, there was a significant positive effect of tool geometry on the sheet surface roughness.

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Effects of Forming Tools and Process Parameters on Surface Roughness in Incremental Sheet Forming, a Review

Cited by 4 publications

References 54 publications

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

Application of X-ray Diffraction for Residual Stress Analysis in Truncated Cones Made by Incremental Forming

Predict the Effects of Forming Tool Characteristics on Surface Roughness of Aluminum Foil Components Formed by SPIF Using ANN and SVR

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