Experimental Investigation of Forming Forces in Frictional Stir Incremental Forming of Aluminum Alloy AA6061-T6

Baharudin, B. T. Hang Tuah; Azpen, Qasim Mhalhal; Sulaima, Shamsuddin; Mustapha, Faizal

doi:10.3390/met7110484

Cited by 25 publications

(15 citation statements)

References 42 publications

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“…The mechanism able to explain this fact involves the change in the friction conditions, as the heat originating from the increase in friction decreases the various forming force values and, as a result, the mechanical behavior of the polymer material may change. This is also consistent with the work presented by Centeno et al [ 8 , 20 ] and Baharudin et al [ 21 ] for metal materials and, in the case of polymers, by Davarpanah et al [ 11 ] for PLA and PVC, by Lozano-Sánchez et al [ 16 ] for PCL and UHMWPE and by Bagudanch et al [ 22 ] for PVC, PC, PP, UHMWPE and PCL.…”

Section: Resultssupporting

confidence: 91%

Process Parameter Effects on Biocompatible Thermoplastic Sheets Produced by Incremental Forming

et al. 2018

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There has been increasing interest in the processes that enable part customization and small-batch production in recent years. The prosthetic sector, in which biocompatible materials are used, is one of the areas that requires these types of processes; Incremental Sheet Forming (ISF) technology can meet these requirements. However, the biocompatible thermoplastic polymers formed by this technology have not yet been tested. Hence, the aim of this paper is to cover this gap in our knowledge by analyzing the effects of process parameters on the ISF process with the aim of optimizing these parameters before the actual production of, in this case, customized prostheses. Tests with polycaprolactone (PCL) and ultra-high molecular weight polyethylene (UHMWPE) were performed. Maximum force, surface roughness and maximum depth were statistically analyzed by means of response surface methodology and survival analysis. Spindle speed and tool diameter were shown to be the most influential process parameters in terms of maximum forming force and surface roughness for both materials. In contrast, survival analysis applied to maximum depth showed a greater influence of tool diameter in PCL sheets and a greater influence of spindle speed in the case of UHMWPE.

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Section: Resultssupporting

confidence: 91%

Process Parameter Effects on Biocompatible Thermoplastic Sheets Produced by Incremental Forming

et al. 2018

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“…The force component, F z , is a major deformation force that acts along a normal to the sheet plane. This force component is responsible for stretching the sheet in a downward direction [26,27]. To know if this force has any effect on roughening of the free surface, a load cell was placed on the forming rig for measurement.…”

Section: Methodsmentioning

confidence: 99%

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

Al‐Ghamdi

Hussain

2019

Metals

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Due to absence of any supporting die, the free surfaces in incremental sheet forming (ISF) experience uneven deformation. This results in rough surfaces, possibly leading to the reduced service life of components. Therefore, it is necessary to analyze and quantify the effects of the application of strain on the free-surface roughness. Moreover, in order to control roughness, both on the free surface and the opposite contact surface, the nature of correlation between the two types of roughnesses needs to be identified by classifying the significance of different process conditions. The present work is a fundamental study to address these points. A series of specimens are produced by subjecting a metallic sheet to a range of ISF strains (13% to 98%). These specimens are then subjected to a number of characterization tests, namely roughness, uniaxial tension, and residual stress tests. The results reveal that the mean free-surface roughness increases non-linearly as the normal strain (stretching + bending) on the free surface increases (where strain state on the surface is as follows: ɛ1 = 0, ɛ2 > 0, γmax = ɛ2 and 1 and 2 are principal directions). The roughness also increases, although linearly, with the post-forming sheet strength, residual stress, and forming force, thereby showing that strain hardening has a direct influence on the roughness in a way that sheet strengthening is achieved at the cost of surface quality. The surface morphology reveals that the free surfaces contained orange peel, slip lines, and micro-voids, with density increasing with strain application, thus indicating the possible influence of tensile stresses on free surface deformation and roughening at an increasing degree with strain. Further analysis of roughness results discloses that the free-surface roughness and the contact-surface roughness are inversely related, because the responses of the two to ISF processing were mutually exclusive. Based on the obtained results, future research directions are also discussed.

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“…Furthermore, electrically-assisted double-sided incremental forming was investigated by Xu [47]. Other heating techniques have been investigated using a halogen lamp in [178,284], induction heating [285][286][287][288], heating generated by friction [80,[289][290][291], and blowing hot air for the purpose of heating [179,180,292,293].…”

Section: Emerging Incremental Forming Methodsmentioning

confidence: 99%

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Trzepieciński

Oleksik

Pepelnjak

et al. 2021

Metals

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Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

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Experimental Investigation of Forming Forces in Frictional Stir Incremental Forming of Aluminum Alloy AA6061-T6

Cited by 25 publications

References 42 publications

Process Parameter Effects on Biocompatible Thermoplastic Sheets Produced by Incremental Forming

Process Parameter Effects on Biocompatible Thermoplastic Sheets Produced by Incremental Forming

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

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