Influence of Single-Point Incremental Force Process Parameters on Forming Characteristics and Microstructure Evolution of AA-6061 Alloy Sheet

Barnwal, Vivek Kumar; Chakrabarty, Shanta; Tewari, Ashish; Narasimhan, K.; Mishra, Sushil

doi:10.1007/s11665-019-04446-9

Cited by 8 publications

(4 citation statements)

References 38 publications

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Section: Resultssupporting

confidence: 60%

“…It was very clear that sheet thickness reduction is maximum for wall angle of 50°and minimum for wall angle of 30°. Thinning was observed more on the wall region of the component as observed by Barnwal et al 17 Localized plastic deformation causes the minimal thickness variation in the later stage. Increased wall angle causes the sheet to be subjected to additional shearing action, resulting in increased thickness reduction and sheet fracture as reported by Honarpisheh et al 18 As observed by Shrivastava et al, 19 the thickness reduction values obtained from experimental studies are consistent with the theoretical cosine law, and it is evident that formability will be highest for materials with larger initial thickness.…”

Section: Thickness Of Formed Componentssupporting

confidence: 52%

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

Mohanraj

Elangovan

Kumar

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Aerospace, automobile and biomedical sector focuses on innovative rapid manufacturing processes, which can enable product customization, reduction in cost and manufacturing lead time. Aerospace, automobile and biomedical industries mostly use magnesium AZ31 and aluminium 6061 alloy materials for manufacturing of products because of their lower elastic modulus, excellent corrosion and fatigue resistance. The conventional sheet metal forming processes often require additional tools like punch and die and would not be economically viable to produce the customized structure for applications. An emerging forming technique known as warm incremental sheet forming process is evolved, which is capable of forming intricate, asymmetrical components at elevated temperature with localized deformation method. The characteristics of warm incremental sheet forming process suggest the need for the investigation of magnesium AZ31 and aluminium 6061 alloy materials for wide application of the process. Experimental investigation on the influence of process parameters on warm incremental sheet metal forming of magnesium AZ31 and aluminium 6061 alloy materials using electric heating technique was studied. Experimental results revealed that magnesium AZ31 and aluminium 6061 alloy sheet metal component formed with incremental depth of 0.1 mm, wall angle of 50° and temperature of 300°C showed maximum formability and thickness reduction with minimum geometrical deviation.

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Section: Resultssupporting

confidence: 60%

Section: Thickness Of Formed Componentssupporting

confidence: 52%

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

Mohanraj

Elangovan

Kumar

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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show abstract

“…Tool size is an essential factor that affects the properties of SPIF components, since increasing the tool diameter causes a decrease in the hardness of AA1100 aluminium [63], whereas decreasing it causes higher formability and a lowering of the forming force of a commercially pure titanium (CP-Ti) sheet [64]. This, together with the vertical depth, significantly affects the thickness homogeneity of the AA-6061 (T6) aluminium alloy sheet after forming [65].…”

Section: Forming Toolmentioning

confidence: 99%

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Trzepieciński

Oleksik

Pepelnjak

et al. 2021

Metals

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Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

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“…During the SPIF process, whether the sheet metal thickness is uniform or not directly affects the final forming quality; hence, thickness uniformity can be considered an indicator of formability to prevent the local thinning from becoming serious. Barnwal et al [10] investigated the formability of the cone by analyzing the thickness strain distribution of the components. This study reveals that the process parameters are likely to influence the texture development, especially for large tool head diameters and vertical pitch values.…”

Section: Introductionmentioning

confidence: 99%

Effects of Process Parameters on the Thickness Uniformity in Two-Point Incremental Forming (TPIF) with a Positive Die for an Irregular Stepped Part

Gao

et al. 2020

Materials

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Incremental sheet forming (ISF) is a novel flexible forming technology with advantages, such as a low forming force, low-energy-consuming equipment, and good forming performance. The lack of available information about the formability of the two-point incremental forming (TPIF) process makes it limited for practical applications. Taking an irregular stepped part as the target part, the effects of process parameters on the thickness uniformity when using TPIF with a positive die for AA1060 aluminum alloy sheets were investigated. First, the set of optimal parameters regarding the diameter of the tool head, feed rate, and the step size were obtained through orthogonal experiments. Furthermore, the optimal parameter set of the number of forming passes, the direction of movement of the forming tool, and the forming angle was determined and the optimal forming result was numerically and experimentally verified. This demonstrated that the parameters affecting the thickness uniformity of the irregular stepped parts were, in descending order, the diameter of the forming tool, the feed rate, and the step size, with corresponding optimal values of 12 mm, 15,000 mm/min, and 0.4 mm, respectively. With an increase of the number of passes and a decrease of the forming angle between adjacent passes, and adopting an alternating clockwise and counterclockwise toolpath, the thickness uniformity of the formed parts was effectively improved.

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Influence of Single-Point Incremental Force Process Parameters on Forming Characteristics and Microstructure Evolution of AA-6061 Alloy Sheet

Cited by 8 publications

References 38 publications

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

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

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Effects of Process Parameters on the Thickness Uniformity in Two-Point Incremental Forming (TPIF) with a Positive Die for an Irregular Stepped Part

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