Effect of Tool Shape on Surface Finish of Components Formed Through Incremental Sheet Forming Process

Abstract

This work explores the effect of tool geometry on surface finish in incremental sheet forming (ISF) process. In the present work, two different tool geometries i.e. hemispherical shaped tool and ellipsoidal shaped tool are considered. Area at tool-sheet contact and scallop height were calculated for both the tool geometries. To assess the effect of tool geometry on the surface finish of the formed components, both analytical and experimental approaches have been used. A test geometry having the shape of frustum of pyramid was considered for the proposed investigation and four surface roughness parameters i.e. arithmetic mean surface roughness (Ra), root mean square surface roughness (Rq), maximum peak-to-valley height (Rt) and average peak-to-valley height (Rz) have been selected as response parameters. Based on the analytical model and experimental investigations, both qualitative and quantitative comparisons had been made among the effects of hemispherical and ellipsoidal tool geometries on surface finish. The investigation deduces that better surface finish of the formed component can be achieved by using ellipsoidal shaped tool rather than the hemispherical shaped tool.