Parameter Optimization for Surface Roughness and Wall Thickness on AA5052 Aluminium alloy by Incremental Forming using Response Surface Methodology

Mugendiran, V.; Gnanavelbabu, A.; Radhika, R.

doi:10.1016/j.proeng.2014.12.442

Cited by 47 publications

(29 citation statements)

References 11 publications

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“…The process parameters are considered significance to the experiment if there is a large angled slope of the straight line. We can see that all the points are relatively closed to the straight line and thus that the data follow a normal distribution [12]. ANOVA was used to determine the optimal input values which allow to minimize the forming force.…”

Section: Experimental Design Optimizationmentioning

confidence: 99%

Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet

Saidi

Giraud-Moreau

Cherouat

et al. 2017

J. Phys.: Conf. Ser.

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Abstract. AINSI 304L stainless steel sheets are commonly formed into a variety of shapes for applications in the industrial, architectural, transportation and automobile fields, it's also used for manufacturing of denture base. In the field of dentistry, there is a need for personalized devises that are custom made for the patient. The single point incremental forming process is highly promising in this area for manufacturing of denture base.The single point incremental forming process (ISF) is an emerging process based on the use of a spherical tool, which is moved along CNC controlled tool path. One of the major advantages of this process is the ability to program several punch trajectories on the same machine in order to obtain different shapes. Several applications of this process exist in the medical field for the manufacturing of personalized titanium prosthesis (cranial plate, knee prosthesis…) due to the need of product customization to each patient.The objective of this paper is to study the incremental forming of AISI 304L stainless steel sheets for future applications in the dentistry field. During the incremental forming process, considerable forces can occur. The control of the forming force is particularly important to ensure the safe use of the CNC milling machine and preserve the tooling and machinery.In this paper, the effect of four different process parameters on the maximum force is studied. The proposed approach consists in using an experimental design based on experimental results. An analysis of variance was conducted with ANOVA to find the input parameters allowing to minimize the maximum forming force. A numerical simulation of the incremental forming process is performed with the optimal input process parameters. Numerical results are compared with the experimental ones.

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Section: Experimental Design Optimizationmentioning

confidence: 99%

Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet

Saidi

Giraud-Moreau

Cherouat

et al. 2017

J. Phys.: Conf. Ser.

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“…Bagudanch et al [21] concluded that the spindle speed and s are the most critical parameters, and the interactions between f and s, t and d, and spindle speed with f also have a significant influence on the surface roughness. Mugendiran et al [22] studied incremental forming to optimize surface roughness by controlling the effects of forming parameters. e obtained results indicated that the primary parameters influencing the arithmetic mean surface roughness value (Ra) are f, spindle speed, and t, excluding the interactions among the three parameters.…”

Section: Introductionmentioning

confidence: 99%

Study of the Effect of Process Parameters on Surface Profile Accuracy in Single‐Point Incremental Sheet Forming of AA1050‐H14 Aluminum Alloy

Dabwan

Ragab

Saleh³

et al. 2020

Advances in Materials Science and Engineering

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Single-point incremental forming is an innovative flexible and inexpensive technique to form sheet products when prototypes or small batches are required. The process allows complex geometries to be produced using a computer numerical control machine, eliminating the need for a special die. This study reports on the effects of four important single-point incremental forming process parameters on produced surface profile accuracies. The profile accuracy was estimated by measuring the side angle errors and surface roughness and also waviness and circularity of the product inner surface. Full factorial design of experiments was used to plan the study, and the analysis of variance was used to analyze and interpret the results. The results indicate that the tool diameter (d), step depth (s), and sheet thickness (t) have significant effects on the produced profile accuracy, while the feed rate (f) is not significant. As a general rule, thin sheets with greater tool diameters yielded the best surface quality. The results also show that controlling all surface quality features is complex because of the contradicting effects of, and interactions between, a number of the process parameters.

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“…Mugenderan et. al [16] had attempting to optimize the metal forming parameters such as surface roughness and sheet thickness after forming which is to obtain minimum surface roughness and maximum wall thickness in incremental forming. Cus and Zuperl [17] briefly present a compensation method in milling in order to take into account tool deflection during cutting condition optimization or tool path generation.…”

Section: Introductionmentioning

confidence: 99%

Parametric Optimization of Robot-based Single Point Incremental Forming Using Taguchi Method

Ismail

Radzman

et al. 2019

IJIE

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Sheet metals forming process is widely used in consumer and industrial products. However, the conventional sheet metal forming has low flexibility and product quality. It also prolongs the time-to-market in producing prototype products that required low costs. Single point incremental forming (SPIF) is one of relatively new sheet metal forming process. The increase interest in new techniques for forming processes and the usage of robotics in the industry has created more researches on the SPIF. Robot-based SPIF is a method of deforming a sheet metal to create designed workpieces by utilising a forming tool that attached to an industrial robot. In this present work, an optimization study for combination of process parameters in robot-based single point incremental forming of aluminum alloy sheet was experimentally investigated using Taguchi method to achieve an excellent surface roughness. A number of forming experiments were conducted using the L18 orthogonal array. Analysis of Variance (ANOVA) was used to identify the most significant process parameters affecting the surface roughness. The results analysis indicates that the optimum process parameters for surface roughness are obtained as 0.3 mm of step size, 150 mm/s of robot speed and 45 degree of wall angle. The most significant process parameter is step size and followed by robot speed. The study revealed the surface quality could be improved by proper selection of process parameters.

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Parameter Optimization for Surface Roughness and Wall Thickness on AA5052 Aluminium alloy by Incremental Forming using Response Surface Methodology

Cited by 47 publications

References 11 publications

Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet

Experimental and numerical study on optimization of the single point incremental forming of AINSI 304L stainless steel sheet

Study of the Effect of Process Parameters on Surface Profile Accuracy in Single‐Point Incremental Sheet Forming of AA1050‐H14 Aluminum Alloy

Parametric Optimization of Robot-based Single Point Incremental Forming Using Taguchi Method

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