Influence of process parameters on surface roughness and forming time of Al-1100 sheet in incremental sheet metal forming

Abstract

Product quality and production time are critical constraints in sheet metal forming. These are normally measured in terms of surface roughness and forming time, respectively. Incremental sheet metal forming is considered as most suitable for small batch production specifically because it is a die-less manufacturing process and needs only a simple generic fixture. The surface roughness and forming time depend on several process parameters, among which the wall angle, step depth, feed rate, sheet thickness, and spindle speed have a greater impact on forming time and surface roughness. In the present work, the effect of step depth, feed rate and wall angle on the surface roughness and forming time have been investigated for constant 1.2 mm thick Al-1100 sheet and at a constant spindle speed of 1300 rpm. Since the variable effects of these parameters necessitate multi-objective optimization, the Taguchi L9 orthogonal array has been used to plan the experiments and the significance of parameters and their interactions have been determined using analysis of variance (ANOVA) technique. The optimum response has been brought out using response surfaces. Finally, the findings of response surface method have been validated by conducting additional experiments at the intermediate values of the parameters and these results were found to be in agreement with the predictions of Taguchi method and response surface method.

On the thinning variations in hydrostatic forming of sheet metal

“…The graphs also show that thickness deformation ratio at point (8,9) is less than at point (5,6,7). In hydrostatic forming technology, the material will contact the die's bottom under the effect of forming liquid pressure.…”

“…Therefore, different methods of sheet metal forming have been researched and developed. This tendency has made a big motivation for studies on sheet technology to be done with considerable achievements [1][2][3][4][5][6]. In sheet metal forming process, thinning variations occur in most areas of the products and considerably affect the product quality, especially in drawing operation [2].…”

Effects of reverse cold rolling on the microstructure, texture and mechanical properties of AA1100 aluminium alloys

“…These alloys have low mechanical strength, which could be eventually increased by strain hardening [2]. Rolling processes are commonly used for this purpose, aiming to obtain sheets, which are traditionally used for the manufacture of insulating coatings, sheets, and kitchen tools [3,4].…”

Ring Rolling speed rolls optimization to improve ring quality and reduce production time

“…Li [16] suggested a guideline for planning the feed rates of the relevant complex profiled Ring Rolling process to improve efficiency and reduce cost. A correlation between the feed rate and the surface roughness of the produced workpiece was analyzed by Mohanty [17].…”