This paper is focused on single point incremental forming (SPIF) of a tailored welded blanks (TWBs) that produced by laser welding process. The SPIF process is a new dieless forming technology, which is a fast and economic solution to prototyping a metal sheet product. In the past, the SPIF researches carried out with the homogeneous metal sheet blank, but now a day, the demand of TWBs is still increased especially for an automotive industry. The aim of this research is to study the formability on the weld line of laser welding TWBs (SUS 304 and St 37) by the SPIF process.
The single point incremental forming process (SPIF) are suited for sheet metal prototyping, because it is a low cost production process that produces sheet metal part without any used of die, and easy to adjust the part’s geometry by change toolpath. But the quality of forming parts is still in doubt. In some applications, such as mould cavity for rapid mould and the medical parts, in this case the inside surface roughness plays an importance role. In this paper, the SPIF process parameters that affected to the inner surface roughness were experimental studied. The investigated parameters are composing of tool feed rate, side overlap, depth step and tool radius. The 2k-p factorial experimental design was used to analyze the interaction between each parameter. The results showed that increasing feed rate and depth step decreased inner surface roughness. Reducing tool rotational speed and feed rate reduced inner surface roughness. So increasing depth step with decreasing side overlap reduced inner surface roughness. The large tool radius and lower side overlap improved inner surface roughness. The large tool radius and higher depth step improved inner surface roughness. And last, reducing tool rotational speed with larger tool radius, the inner surface roughness is decreased.
Single point incremental forming (SPIF) process is the latest sheet metal forming technique, which developed in the around 1990, this process could generates a local strain on a sheet metal by mean of small rotation forming tool travel follow CNC toolpath on sheet metal blank to form a shell part. The incredible elongating without failure occurs is the main advantage of this process. This paper attempt to explain the deformation mechanism of steel sheet that formed by SPIF in the metallurgical views. The different degree of deformation were investigated by optical microscope, the grain size deformation was used as a data for math modeling of the deformation mechanism.
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