Comparison of incremental sheet metal forming process using newly designed multipoint tool with the existing single point tool by optimization and characterization methods on austenite stainless steel 202

Abstract

Incremental Sheet metal Forming (ISF) is a reliable process of converting a blank to work piece with better outputs compared to conventional forming process. The flexibility of ISF in producing the rapid prototype based on the customer needs is increased which is also desirable in the industry. But Single Point Incremental Forming (SPIF) process takes more time to form a product and hence the longer time is a barrier in implementing this process in industries. In this research work, the ISF process was made on sheet metal SS 202 using a newly designed multi-point tool and the obtained outputs were compared with the same material of sheet metal formed by traditionally available single point tool. This Multi Point Incremental Forming (MPIF) process takes lesser process time to give better formability, improved wall angle and good surface roughness. The input process parameters selected for the process are type of tool, speed, feed, Vertical Step Depth (VSD), and lubrication. They are arranged by using the taguchi Design of Experiments (DOE) approach. The responses considered are wall angle, formability, surface roughness, spring back and forming time. The multiple outputs obtained were optimized by Grey Relational Analysis (GRA) to predict the superior parameter. Confirmation test was also made to validate the output result. Fractography analysis was carried out to predict the fracture mechanism obtained during the forming process. The surface topography was also made on the surface of the formed area of the sheet metal. This research work concludes that newly designed MPIF outperforms SPIF.

Investigations on the formability, tensile properties, TEM, 3D-surface roughness and corrosion behaviour on Ti–6Al–4V alloy sheets during single point and multi point incremental forming process

“…Ramkumar et al (2021) carried out an experimental investigation on FLD, fractography and 3D-surface roughness on Cr/Mn/Ni/Si-based stainless steel using SPIF and multi-point incremental forming (MPIF) process; the sheet is deformed using the MPIF process and it was observed that higher plastic deformation and good surface finish were achieved as compared with those achieved using the SPIF process because of more contact area in MPIF process. Kathalingam et al (2021) studied and reported that austenite stainless steel achieved good surface finish, the grease used as lubricant in MPIF process as compared with SPIF process.…”

Investigation of surface roughness in multi point incremental sheet metal forming

“…Few research works are available in MPIF [15][16][17]. In this study, three input parameters namely feed, speed and step depth are used to experimentally study their influence on surface roughness.…”

“…The forming operation is carried out up to the fracture point of the sheet metal part. The input parameters selected based on previous works [17] are selected and their levels are shown in Table 1. Step depth C 0.2 0.4 0.6 mm Total 9 experiments were conducted and coconut oil is used as the lubricant for all the experiments.…”

Investigations on formability of tailor laminated sheets in single point incremental forming

“…Basak et al 21 found higher formability for lower tool diameter and step depth, while higher feed rate increased productivity at the cost of surface quality in SPIF of AA6061 sheet. Kathalingam et al 22 achieved higher formability with good surface finish and less forming time in case of MPIF compared to that of SPIF process. Incremental forming of laminated sheets made of metallic and polymeric sheets was also studied by researchers as discussed below.…”