Experimental investigation and optimization of surface roughness in negative incremental forming

Kumar, Ajay; Gulati, Vishal

doi:10.1016/j.measurement.2018.08.078

Cited by 47 publications

(19 citation statements)

References 15 publications

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“…The process parameters play vital role for selecting the suitable hardware for the safe and optimal execution of the ISF process [1,8]. Some researchers studied the effects of different common process parameters like tool diameter, wall angle, lubrication, sheet thickness and spindle speed on forming forces as reported in Table 5.…”

Section: Influence Of Process Parameters On Forming Forcesmentioning

confidence: 99%

“…Lubrication is an important input factor in the ISF process which decreases friction at the contact zone of tool and blank [1,8,60]. Lubrication is also helpful for enhancing tool life by dissipating heat from the forming zone.…”

Section: Influence Of Lubricationmentioning

confidence: 99%

“…Lubrication is also helpful for enhancing tool life by dissipating heat from the forming zone. Lubrication also removes waste materials from the forming zone [1,3]. Hence, lubrication is the key to safe forming of components during the forming processes [82].…”

Section: Influence Of Lubricationmentioning

confidence: 99%

“…In the engineering field, parts are made of sheet metal particularly through conventional forming methods such as stretch forming, deep drawing, shearing, blanking and bending, etc. These conventional forming processes become time-consuming and uneconomical due to the direct involvement of dedicated forming dies and punches [1,2]. To produce a batch size of about 5000 parts, approximately 200 stamping dies are used in the aerospace industry each year.…”

Section: Introductionmentioning

confidence: 99%

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Forming force in incremental sheet forming: a comparative analysis of the state of the art

Kumar

Gulati

Kumar

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Incremental sheet forming (ISF) significantly exempts use of expensive dies and reduces tooling cost for manufacturing complex parts in the field of sheet metal forming which makes it suitable for manufacturing prototypes and low volume production as compared to other traditional sheet metal forming processes. ISF also finds suitability for producing components of old machinery, which are otherwise very difficult to form due to the unavailability of forming dies. Moreover, the incremental nature of the process and local deformation of the sheet ensures higher formability and lower required forming force. To take advantages of lower required forming force, it is important to minimize and estimate forming force through the manipulation of the parameters for the safe utilization of hardware. In this review article, a literature survey was carried out quantitatively to study different aspects of ISF, especially to show different process parameters and techniques that affect the forming forces significantly. The current state of the art of the ISF process has been discussed with detailed analysis of process capabilities and limitations in terms of forming forces. Influences of different process parameters and forming techniques have also been studied on forming forces. Some parameters have shown their significance to control the forming force in order to preserve forming machinery. A lack of focus was found on effects of some important forming process parameters and methods, which could have been crucial for safe utilization of forming hardware. A number of guidelines have been recommended for future research work. Appropriate guidelines have also been suggested regarding the relationship between process parameters and forming forces developed during the process in order to ensure the applicability of the ISF process on the industrial scale.

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Section: Influence Of Process Parameters On Forming Forcesmentioning

confidence: 99%

Section: Influence Of Lubricationmentioning

confidence: 99%

Section: Influence Of Lubricationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Forming force in incremental sheet forming: a comparative analysis of the state of the art

Kumar

Gulati

Kumar

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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“…The forming tool marks and the grain boundaries were identified as the reason for surface roughness increase. Kumar et al [ 29 ] investigated the influence of process parameters on the surface quality. of the formed parts.…”

Section: Introductionmentioning

confidence: 99%

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Murugesan

Jung

2021

Materials

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The single-point incremental forming process (SPIF) is one of the emerging manufacturing methods because of its flexibility in producing the desired complex shapes with higher formability at low-cost compared to traditional sheet forming methods. In this research work, we experimentally investigate the forming process to determine the influence of process parameters and their contribution to enhancing the formability without causing a fracture by combining the design of experiments (DOE), grey relational analysis (GRA), and statistical analysis of variance (ANOVA). The surface morphology and the energy dispersive X-ray spectroscopy (EDS) method are used to perform elemental analysis and examine the formed parts during three forming stages. The DOE procedure, a central composite design with a face-centered option, is devised for AA3003-H18 Al alloy sheet for modeling the real-time experiments. The response surface methodology (RSM) approach is adopted to optimize the forming parameters and recognize the optimal test conditions. The statistically developed model is found to have agree with the test measurements. The prediction model’s capability in R2 is computed as 0.8931, indicating that the fitted regression model adequately aligns with the estimated grey relational grade (GRG) data. Other statistical parameters, such as root mean square error (RMSE) and average absolute relative error (AARE), are estimated as 0.0196 and 2.78%, respectively, proving the proposed regression model’s overall closeness to the measured data. In addition, the prediction error range is identified as −0.05 to 0.05, which is significantly lower and the residual data are distributed normally in the design space with variance and mean of 3.3748 and −0.1232, respectively. ANOVA is performed to understand the adequacy of the proposed model and the influence of the input factors on the response variable. The model parameters, including step size, feed rate, interaction effect of tool radius and step size, favorably influence the response variable. The model terms X2 (0.020 and 11.30), X3 (0.018 and 12.16), and X1X2 (0.026 and 9.72) are significant in terms of p-value and F-value, respectively. The microstructural inspection shows that the thinning behavior tends to be higher as forming depth advances to its maximum; the deformation is uniform and homogeneous under the predefined test conditions.

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Incremental Sheet Forming – A State‐of‐Art Review

Rudramamba,

Rami Reddy,

Nakka

2023

Handbook of Flexible and Smart Sheet Forming Techniques

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Experimental investigation and optimization of surface roughness in negative incremental forming

Cited by 47 publications

References 15 publications

Forming force in incremental sheet forming: a comparative analysis of the state of the art

Forming force in incremental sheet forming: a comparative analysis of the state of the art

Formability and Failure Evaluation of AA3003-H18 Sheets in Single-Point Incremental Forming Process through the Design of Experiments

Incremental Sheet Forming – A State‐of‐Art Review

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