Abstract
Incremental forming is a flexible sheet metal forming process which is performed by utilizing simple tools to locally deform a sheet of metal along a predefined tool path without using of dies. This work presents the single point incremental forming process for producing pyramid geometry and studies the effect of tool geometry, tool diameter, and spindle speed on the residual stresses. The residual stresses were measured by ORIONRKS 6000 test measuring instrument. This instrument was used with four angles of (0º,15º,30º, and 45º) and the average value of residual stresses was determined, the value of the residual stress in the original blanks was (10.626 MPa). The X-ray diffraction technology was used to measure the residual stresses. The sheet material used was Aluminum alloy (AL1050) with thickness of (0.9 mm). The experimental tests in this work were done on the computer numerical control (CNC) vertical milling machine. The extracted results from the single point incremental forming process were analyzed using analysis of variance (ANOVA) to predict the effect of forming parameters on the residual stresses. The optimum value of the residual stresses (55.024 MPa) was found when using the flat end with round corner tool and radius of (3 mm), wall angle of (55°) and a rotational speed of the tool of (800 rpm). The minimum value of the residual stresses (24.389MPa) was found when using hemispherical tool with diameter of (12 mm), wall angle of (45°) and a rotational speed of the tool of (800 rpm).
Highlights
Single Point Incremental Forming (SPIF) process has been developed from sheet metal spinning, sheet metal shear moving and hammering with included computer numerical control (CNC) system to control the forming tool motion [1]
The results showed that it is possible to rely on the incremental sheet metal forming process and commercialized as an alternative method to traditional deformation processes
Al 1050 sheet were incremental formed under different forming tool geometry and their effects studies, the following conclusions were drawn from the study: 1-From the extracted results, the increase of the tool diameter and the rotational speed of the tool will reduce the residual stresses
Summary
Single Point Incremental Forming (SPIF) process has been developed from sheet metal spinning, sheet metal shear moving and hammering with included CNC system to control the forming tool motion [1]. SPIF is a comparatively recent bed sheet forming process which enables forming of complicated shapes without specific dies utilizing only a single point tool and a standard three-axis CNC machine [2]. SPIF is a progressive and adaptable bed sheet metal-forming technology that uses layered manufacturing basis. That changes the part geometry data for a several parameters of 2D layers, and after that the plastic-local deformation is done layer-by-layer over the CNC machine motions of the simple forming. Tool to manufacture products with complicated shapes as demonstrated in figure (1) [3, 4]
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