Experimental Investigation of SPIF Process for Conical Frustum

Abstract

In sheet metal industries, single point incremental forming (SPIF) is a popular technology for quick prototyping and small series manufacturing techniques. In producing specific components with complicated geometries, the technique has become known for its flexibility, effectiveness, and simplicity of usage. The objective of this research work is to carry out the numerical investigation of the SPIF process to study the effect of different parameters on the formability for truncated cone. Al 1060 grade of aluminium is used for this study which is commonly used for kitchenware, reflectors, electronic components etc; where strength is not a major concern. Three dimensional models were developed for different set of parameters using commercial finite element software ABAQUS 6.13 with Dynamic/Explicit solver using solid mechanics model. Taguchi analysis has been carried out to find the effect of parameters (Tool rotational speed, Feed, Step size, Tool diameter and Wall angle) on thickness reduction. Each parameter was varied for three levels and L9 orthogonal array was used. The ANOVA tool has been used to summarize the contribution of each variable. Results have been compared with reported experimental results for validation. The process modelling is concluded with a brief overview of approaches for improving part quality.