Effects of rolling ball tool parameters on roughness, sheet thinning, and forming force generated during SPIF process

Abstract

Single-point incremental forming (SPIF) is a rising technology used shaping sheet-metals. The emergence of this manufacturing process is due to its capability to produce parts with complex shape at lower cost. The present contribution is focused on the presentation of a new designed rolling ball forming tool that can improve (SPIF) operations. For that, the effects of process working parameters on a set of process qualification criteria when forming of AA1050 aluminum alloy sheets is presented. Deep analyses treating impacts of tool step down, tool rolling ball diameter, and tool feed rate on the process responses such as forming axial forces, surface roughness, and sheet thinning are made. The analysis is based on statistical methodologies which made it possible to establish, using the multiple regression method, predictive analytical models for the different responses.