Experimental investigations of warm incremental sheet forming process on magnesium AZ31 and aluminium 6061 alloy

Mohanraj, R.; Elangovan, S.; Kumar, S. Pratheesh

doi:10.1177/14644207221110783

Cited by 4 publications

(3 citation statements)

References 22 publications

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“…The same trend was observed for spring back as well. Recently, Mohanraj et al [33] performed WISF on magnesium AZ31 and aluminum 6061 alloys and achieved better formability and an exact shape at 300 • C.…”

Section: Introductionmentioning

confidence: 99%

Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study

Singh

Kumar

Pande

et al. 2023

Metals

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Incremental sheet forming (ISF) requires no or partial dies for sheet metal fabrication and is widely used for small batch production. In this process, necking is either suppressed or delayed due to the localized nature of tool–sheet contact; hence, more strains than conventional stamping and deep drawing are obtained. In the present study, two variations of ISF, namely cold ISF (CISF) and warm ISF (WISF), are compared. First, FEA modeling is carried out on ABAQUS to reach the forming forces involved in the process. It is found that WISF reduces the forming forces. The temperature for WISF is maintained at 180 °C. Following the simulation analysis, tests are carried out. The forming force in WISF is 55.77% less than that in CISF. The part fabricated by CISF is slightly more substantial than that by WISF; however, more forming depth can be achieved by WISF. There is a more uniform thickness distribution in the case of CISF than in WISF. However, the surface quality of the CISF product is inferior to that of WISF. It is observed that there is reduced forming force, increased formability, and better strain distribution in WISF compared to CISF. However, post-processing heat treatment and surface polishing of the formed parts is required to restore their mechanical properties.

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Section: Introductionmentioning

confidence: 99%

Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study

Singh

Kumar

Pande

et al. 2023

Metals

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“…The investigation of the forming behaviour under different processes like stretch forming, 16,17 deep drawing 18,19 and incremental sheet metal forming 20,21 is essential as the material undergoes different deformation modes under these processes. Especially, the investigation of the deep drawing behaviour of CP Ti is of much interest for the fabrication of sheet metal components.…”

Section: Introductionmentioning

confidence: 99%

Deep drawability of electron beam welded tailored blanks of commercially pure titanium thin sheets

Prakash

Panda

Roy

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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In this work, commercially pure titanium tailor-welded blanks (TWBs) were fabricated from sheets of thicknesses 1.0 mm (Ti1.0) and 1.2 mm (Ti1.2) using electron beam welding (EBW). It was observed that the titanium base materials had an equiaxed microstructure, whereas the FZ of the weld consisted of coarsened prior β grains with internal α substructures. Transverse and longitudinal tensile tests were conducted to evaluate weld integrity and weld properties, respectively. The deep drawing behaviour of both the base materials and TWB had been investigated by conducting laboratory-scale deep drawing tests. The limiting drawing ratios (LDR) of the Ti1.0 and Ti1.2 base materials were 2.14 and 2.21, respectively. The LDR of TWB was 2.14, which was same as that of the Ti1.0 base material. The CPB06 yield criterion and weld properties were incorporated in the FE modelling to study the deep drawing behaviour of the TWB for the first time. The FE model successfully predicted the non-uniform material flow and thickness distribution in the deep drawn TWB. Moreover, the weld line movement was found to be towards the Ti1.0 side at the cup top region and towards the Ti1.2 side at the cup bottom of the TWB deep-drawn cup.

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“…It is possible to prevent the formation of bump structures due to delamination during SPIF of laminated sheets by making the right tool path selections. Mohanraj et al 21 experimentally investigated the effects of process parameters on warm incremental sheet metal forming of aluminum 6061 and magnesium AZ31 alloy materials using electric heating technique. From the experimental findings, the authors concluded that sheet metal components made of AZ31 and AA6061 alloys could be formed with the greatest degree of formability and thickness reduction while exhibiting the least amount of geometrical deviation when using 50° wall angle and 300°C temperature and 0.1 mm incremental depth.…”

Section: Introductionmentioning

confidence: 99%

Optimization and prediction of incremental sheet forming parameters of Titanium grade 5 sheet using a response surface methodology and artificial neural network

Ajay¹,

Elangovan

AS³

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Single point incremental forming (SPIF) is an advanced, flexible, and cost-effective approach for producing complicated sheet metal objects quickly. Because of its low equipment cost, the process is best suited toward low or medium quantity batch production as the conventional stamping method remains cost-effective only for mass manufacture. During SPIF formation of titanium grade 5 materials, a response surface methodology and artificial neural network (ANN) model was created to optimize and estimate wall angle (Ømax) and average surface roughness ( Ra). The ANN model is developed using feed forward back propagation networks. Various combinations of transfer functions and number of neurons were used to create the ANNs (3- n-1, 3- n-2). The confirmation runs have been used to ensure that the ANN anticipated and practical findings have been in agreement. The generated ANN model (3- n-1) was capable of accurately forecasting the results of the experiment, with an overall R-value and Mean Square Error (MSE) of 0.99987 and 0.010905 for Ra, and 0.99999 and 0.00700 for wall angle. The best 3- n-2 models has an average R-value of 0.99992 and MSE of 0.05532, respectively. As a consequence of rapid ANN modeling technique, it became discovered that technical effort inside the SPIF process could be decreased.

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Experimental investigations of warm incremental sheet forming process on magnesium AZ31 and aluminium 6061 alloy

Cited by 4 publications

References 22 publications

Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study

Robot-Assisted Cold and Warm Incremental Sheet Forming of Aluminum Alloy 6061: A Comparative Study

Deep drawability of electron beam welded tailored blanks of commercially pure titanium thin sheets

Optimization and prediction of incremental sheet forming parameters of Titanium grade 5 sheet using a response surface methodology and artificial neural network

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