Parametric Effects of Single Point Incremental Forming on Hardness of AA1100 Aluminium Alloy Sheets

Abstract

When using a unique tool with different controlled path strategies in the absence of a punch and die, the local plastic deformation of a sheet is called Single Point Incremental Forming (SPIF). The lack of available knowledge regarding SPIF parameters and their effects on components has made the industry reluctant to embrace this technology. To make SPIF a significant industrial application and to convince the industry to use this technology, it is important to study mechanical properties and effective parameters prior to and after the forming process. Moreover, in order to produce a SPIF component with sufficient quality without defects, optimal process parameters should be selected. In this context, this paper offers insight into the effects of the forming tool diameter, coolant type, tool speed, and feed rates on the hardness of AA1100 aluminium alloy sheet material. Based on the research parameters, different regression equations were generated to calculate hardness. As opposed to the experimental approach, regression equations enable researchers to estimate hardness values relatively quickly and in a practicable way. The Relative Importance (RI) of SPIF parameters for expected hardness, determined with the partitioning weight method of an Artificial Neural Network (ANN), is also presented in the study. The analysis of the test results showed that hardness noticeably increased when tool speed increased. An increase in feed rate also led to an increase in hardness. In addition, the effects of various greases and coolant oil were studied using the same feed rates; when coolant oil was used, hardness increased, and when grease was applied, hardness decreased.

Recent Developments and Future Challenges in Incremental Sheet Forming of Aluminium and Aluminium Alloy Sheets

“…Table 2 presents the typical lubricants used in the incremental sheet forming of aluminium and aluminium alloy sheets. cold forming [32] mineral oil 2219-O and 2219-T6 cold forming [29] without lubrication 3003 cold forming [24] without lubrication 1050 cold forming [220] oil 7075-T0 cold forming [195] 10w30 servo oil 5754 H22 cold forming [206] machine oil AlMgSi0.5 cold forming [148] Weicon AL-M paste 1050 cold forming [214] Moly Slip AS40 paste 1050 cold forming [214] oil 1050-O, 1050-H24, 6082 hot forming [221] mechanical oil 5052-H32 hot forming [222] Mineral oil (Total Finarol B 5746) 1050 cold forming [214] Moly Slip HSB paste 1050 cold forming [214] SAE 30 oil 1050 cold forming [214] Graphite powder + mineral oil (1:4) 7075-O hot forming [223] SAE 0W-4 6061-T6 hot forming [194] water-oil emulsion cutting fluid 3003-H14 cold forming [197] graphite 33 5182 hot forming [224] solid lubricant (stick wax lubricant) 5052-H32 cold forming [199] MoS 2 5083 hot forming [225] MoS 2 5055 hot forming [226] without lubrication 1050 hot forming [227] graphite 6061 hot forming [228] solid graphite powder and lithium grease with scale 1:1 1050 H14 cold forming [193] 20W-50 1050 H14 cold forming [193] machine oil AlMn1Mg1 foil cold forming [142,143] mineral oil 1050-O cold forming [185] coolant oil, Gp Grease Calcium, Supergrees EP2, Zinol grease AA1100 cold forming [229]…”

Investigation of Surface Roughness in Incremental Sheet Forming of Conical Drawpieces from Pure Titanium Sheets

“…The purpose of most studies is to determine the effect of the process parameters on the quality of the surface that was in contact with the tool. Various approaches are taken to optimise the surface roughness by controlling four machining parameters, i.e., tool rotational speed, tool size, feed rate and step size, and the use of an appropriate lubricant [30]. Sisodia and Kumar [27] formed conical drawpieces from AA1050 aluminium alloy sheets.…”

Finite Element Simplifications and Simulation Reliability in Single Point Incremental Forming

“…Since the process is rather distinct in comparison to other processes of sheet metal forming, special design rules were presented by Afonso et al [ 5 ]. The process was first used solely for the production of metal parts [ 6 , 7 , 8 ], but in recent years, various polymer materials have also been successfully processed by IF technologies [ 9 ].…”