Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

Abstract

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

Optimizing the five magnetic abrasive finishing factors on surface quality using Taguchi-based grey relational analysis

“…The spindle speed produced the highest grade value at, respectively, of 220, 580, 1150 rpm, because the centrifugal force increased, pushing the abrasives farther away from the tool center. In previous studies, the spindle speed increased, bht the improvement in HV became less [36,39,58]. Particles size in this work results maximum grade with big paticles size (125-250) μm and reduces continuously with particles size (63-125) μm and minimum results of grade at (20-63) μm.…”

“…As shown in figure 5, the first explains the maximum precentage change in grade with respect to voltage (30,10,20) volt respectivelly. The scientific explanation of minimum change in surface roughness at 20 voltage belongs to experiments that results of %Δ SR was small values at experiments (11)(12)(13)(14)(15)(16)(17) at table 7, but the percentage %ΔHV consistently increased as the voltage was raised and thats noticed in previous studies [36,39]. The scientific explanation for the direct relationship between %ΔHV and voltage is that an increased voltage Rotational speed and time 38% * Hameed [28] Time and current 44% Xie et al [30] Speed, time and particles size 66% * Present work…”

“…Singh et al [35] improved the microhardness surfaces of specimens using four input parameters (mesh size, speed, time and abrasive weight). Microhardness was studied by Ahmed et al [36], MAF process was utilized after Single Point Incremental Forming (SPIF) as a finishing process with four input parameters (speed, feed rate, gap and current). Nahy and Kadhum [37] proposed studying six input parameters (oil viscosity, powder quantity, gap distance, pole diameter, rotational speed and current), but four parameters common to our work.…”

Experimental Investigation of Dimensional Accuracy in Non-traditional Sheet Metal Spinning Process for Producing Rectangular Spun Part

“…The dimensional accuracy error can be well-defined as the distance error between the theoretical and experimental points on the surface in the spun part, where there is a distance error between the new geometry of the spun part and the design shape of the spun part assigned to the nature of the process [7].…”

Investigation of the Effect of SPIF Parameters on the Thickness of Al 2024 Alloy

“…Conventional forming processes require positive and negative dies to produce any product, which is expensive, especially when the product geometry is complex. This challenge can be eliminated or reduced using the incremental sheet metal forming processes because they do not require a complex die design, and one die can produce different geometries of the products [1,2]. In particular, there are three types of incremental sheet metal forming processes: single-point incremental forming, double-side incremental forming, and multi-point incremental forming [3].…”