Modeling and Optimization of Surface Roughness in Incremental Sheet Forming using a Multi-objective Function

Liu, Zhaobing; Liu, Sheng; Li, Yanle; Meehan, Paul A.

doi:10.1080/10426914.2013.864405

Cited by 74 publications

(33 citation statements)

References 17 publications

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“…This is in accordance with results of Hagan and Jeswiet et al [10]. In general, observations of the surface roughness change are in accordance with the results of obtained by Liu et al [43]. They concluded that surface roughness on the external noncontact surface is always higher than that of the internal tool-sheet contact surface.…”

Section: Surface Roughnesssupporting

confidence: 92%

“…Small areas of galling with a wavy appearance are also visible on the internal surface ( Figure 6). In SPIF, the surface finish on the inner surface can be mainly be characterized as a resultant of large-scale waviness created by the forming path [43]. The surface roughness of the outer surface is mainly caused by large surface strains, which usually leads to an orange peel phenomenon ( Figure 6).…”

Section: Surface Roughnessmentioning

confidence: 99%

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Residual Stresses and Surface Roughness Analysis of Truncated Cones of Steel Sheet Made by Single Point Incremental Forming

Slota

Krasowski

Kubit

et al. 2020

Metals

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The dimensional accuracy and mechanical properties of metal components formed by the Single Point Incremental Forming (SPIF) process are greatly affected by the prevailing state of residual stress. An X-ray diffraction method has been applied to achieve an understanding of the residual stress formation caused by the SPIF process of deep drawing a quality steel sheet drawpiece. The test object for an analysis of residual stress distribution was a conical truncated drawpiece with a slope angle of 71 • and base diameter of the cone of 65 mm. The forming process has been carried out on a 3-axis HAAS TM1P milling machine. Uniaxial tensile tests have been carried out in the universal tensile testing machine to characterize the material tested. It was found that the inner surface of the drawpiece revealed small linear grooves as a result of the interaction of the tool tip with the workpiece. By contrast, the outer surface was free of grooves which are a source of premature cracking. The stress profile exhibits a nonlinear distribution due to different strengthening of the material along the generating line of the truncated conical drawpiece. The SPIF parts experienced a maximum residual stress value of about 84.5 MPa.

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Section: Surface Roughnesssupporting

confidence: 92%

Section: Surface Roughnessmentioning

confidence: 99%

Residual Stresses and Surface Roughness Analysis of Truncated Cones of Steel Sheet Made by Single Point Incremental Forming

Slota

Krasowski

Kubit

et al. 2020

Metals

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show abstract

“…Forming and stress measurement: (a) ISF Schematic, (b) a formed geometry with the state of strain, (c) the tool path, and (d) the measurement of residual stress along with the state of residual stress. The design of experiments (DoE) is a statistical approach that has been frequently applied in sheet metal forming to analyze the process parameters effects and for finding optimum process conditions for single or multiple objectives [23,24]. This approach was therefore applied for the present investigations.…”

Section: Methodsmentioning

confidence: 99%

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

Al‐Ghamdi

Hussain

2019

Metals

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Due to absence of any supporting die, the free surfaces in incremental sheet forming (ISF) experience uneven deformation. This results in rough surfaces, possibly leading to the reduced service life of components. Therefore, it is necessary to analyze and quantify the effects of the application of strain on the free-surface roughness. Moreover, in order to control roughness, both on the free surface and the opposite contact surface, the nature of correlation between the two types of roughnesses needs to be identified by classifying the significance of different process conditions. The present work is a fundamental study to address these points. A series of specimens are produced by subjecting a metallic sheet to a range of ISF strains (13% to 98%). These specimens are then subjected to a number of characterization tests, namely roughness, uniaxial tension, and residual stress tests. The results reveal that the mean free-surface roughness increases non-linearly as the normal strain (stretching + bending) on the free surface increases (where strain state on the surface is as follows: ɛ1 = 0, ɛ2 > 0, γmax = ɛ2 and 1 and 2 are principal directions). The roughness also increases, although linearly, with the post-forming sheet strength, residual stress, and forming force, thereby showing that strain hardening has a direct influence on the roughness in a way that sheet strengthening is achieved at the cost of surface quality. The surface morphology reveals that the free surfaces contained orange peel, slip lines, and micro-voids, with density increasing with strain application, thus indicating the possible influence of tensile stresses on free surface deformation and roughening at an increasing degree with strain. Further analysis of roughness results discloses that the free-surface roughness and the contact-surface roughness are inversely related, because the responses of the two to ISF processing were mutually exclusive. Based on the obtained results, future research directions are also discussed.

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“…Since Box-Behnken designs have fewer design points, they are less expensive to run than other designs with the same number of factors. This design was also proved to be feasible for ISF process by many researchers [17,22,23]. Hence, a Box-Behnken experimental design was conducted to evaluate the effects of process parameters on deformation energy and geometric accuracy.…”

Section: Response Surface Methodology With Box-behnken Designmentioning

confidence: 99%

Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

Daniel

et al. 2015

Int J Adv Manuf Technol

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Incremental sheet forming (ISF) is a promising manufacturing process that features benefits of reduced forming forces, enhanced formability and greater process flexibility. It also has a great potential to achieve economic payoff for rapid prototyping applications and for small quantity production in various applications. However, limited research has been conducted from the sustainability point of view, particularly for energy consumption. More consumed energy will generate more heat and affect tool and product wear. Also, geometric accuracy is still one of the dominant limits for the further development and commercialization of the ISF technology. Therefore, the aim of this study is to investigate how different process parameters affect the consumed energy during the forming process and also find the optimal working condition for lower deformation energy with higher geometric accuracy. A Box-Behnken design of 27 tests for pyramidforming processes have been performed for a multi-objective optimisation that considers four factors: step down, sheet thickness, tool diameter and wall angle at three levels. The deformation energy during the forming process was calculated based on the measured forming forces. It was found that the deformation energy heavily depends on the sheet thickness because of higher plastic energy required to deform the material. Increasing step-down size within a limited range or decreasing the wall angle is also an effective approach to reduce the deformation energy. Moreover, the effects of various process parameters on the global geometric accuracy have also been investigated. The geometric error has been empirically predicted by quadratic equations giving the influence of the most influential forming parameters. It was concluded that the geometric quality is largely determined by the quadratic effect of wall angle, the linear effect of sheet thickness and the interaction effect of thickness and step down. Finally, the optimal working conditions for both independent and simultaneous minimisation of deformation energy and geometric error during the pyramid-forming process are provided.

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Modeling and Optimization of Surface Roughness in Incremental Sheet Forming using a Multi-objective Function

Cited by 74 publications

References 17 publications

Residual Stresses and Surface Roughness Analysis of Truncated Cones of Steel Sheet Made by Single Point Incremental Forming

Residual Stresses and Surface Roughness Analysis of Truncated Cones of Steel Sheet Made by Single Point Incremental Forming

On the Free-Surface Roughness in Incremental Forming of a Sheet Metal: A Study from the Perspective of ISF Strain, Surface Morphology, Post-Forming Properties, and Process Conditions

Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

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