An Experimental Investigation of Surface Quality in Single Point Incremental Forming of Cu-Al Composite Sheets

Abstract

Single-point incremental forming (SPIF) has been developed as a customized substitute of traditional sheet metal forming techniques. SPIF is a great method for rapidly prototyping sheet metal objects, although it faces challenges in achieving surface quality and thickness distribution. In this investigation, sheets of Cu-Al bimetallic composite were formed utilizing a hemispherical-headed tool with a variety of step depths, spindle speeds, forming speeds, layer arrangements, and lubrication types. Surface roughness and minimum thickness were evaluated as response parameters in relation to the significance of process variables. The best surface quality was attained with 0.4 mm step depth, 750 mm/min forming speed, and 1500 rpm spindle speed with liquid lubrication support for both types of layer arrangements. Layer arrangement and lubricant type were the decisive factors for the minimum thickness response parameters.