Complexity-Based Analysis of the Effect of Forming Parameters on the Surface Finish of Workpiece in Single Point Incremental Forming (SPIF)

Ali Akhavan Farid,Shin Shen Foong,Ondrej Krejcar,Hamidreza Namazi

doi:10.3390/fractalfract5040241

Abstract

Nowadays, the manufacturing industry is focused on newer modern manufacturing methods, such as single point incremental forming (SPIF). The popularity of the SPIF process in the manufacturing industry is increasing due to its capability for rapid prototyping, forming complex geometry with simple steps, and customizing products for customers. This study investigates the effect of forming parameters (feed rate and step size) on the surface structure of the aluminum AA6061 sheet. We employ fractal theory to investigate the complexity of deformed surfaces. Accordingly, we study the relationship between the complexity and roughness of the deformed surface. The results show that the complexity and roughness of the deformed surface vary due to the changes in forming parameters. Fractal analysis can be further employed in other manufacturing processes to investigate the relation between the complexity and roughness of processed surfaces.

Highlights

In recent years, the application of single point incremental forming (SPIF) has extended for rapid prototyping because unlike conventional forming, it does not require component-specific tools, such as die.The process of SPIF can be done just by modifying available CNC machines that make it suitable for small-scale productions with lower cost and energy consumption, compared to conventional forming, which is only sensible for mass production [1]
We investigated how the complexity of the deformed surface changes with its roughness
The results indicated that the complexity and roughness of formed surfaces varied with the variations in the forming parameters

Summary

Introduction

The application of SPIF has extended for rapid prototyping because unlike conventional forming, it does not require component-specific tools, such as die.The process of SPIF can be done just by modifying available CNC machines that make it suitable for small-scale productions with lower cost and energy consumption, compared to conventional forming, which is only sensible for mass production [1]. The application of SPIF has extended for rapid prototyping because unlike conventional forming, it does not require component-specific tools, such as die. Since the demand for using SPIF is increasing, it is helpful to evaluate the effects of the forming parameters to improve product quality. In this process, the CNC machine, rounded tip tool, and metal sheet holder, which consist of a clamping plate and support plate, are required. A conical tool with a rounded tip tool can be mounted to the machine spindle to perform a small series of incremental deformation processes on the clamped metal sheet until the desired shape is achieved.

Methods

Results

Conclusion