Abstract
Incremental Sheet Metal Forming (ISMF) is a modern sheet metal forming technology which offers the possibility of manufacturing 3D complex parts of thin sheet metals using the CNC milling machine. The surface quality is a very important aspect in any manufacturing process. Therefore, this study focuses on the resultant residual stresses by forming parameters, namely; (tool shape, step over, feed rate, and slope angle) using Taguchi method for the products formed by single point incremental forming process (SPIF). For evaluating the surface quality, practical experiments to produce pyramid like shape have been implemented on aluminum sheets (AA1050) for thickness (0.9) mm. Three types of tool shape used in this work, the spherical tool gave higher residual stresses than other types, also three levels for each of step over and feed rates utilized. It found that residual stresses was raised up with increasing the step over and feed rate values, the effect of these variables studied on two slope angles. By using analysis of variance method (ANOVA) found that the most influential parameter is step over with (59.18%) and (65.42%) for both slop angles; (α=45°) and (α=55°) respectively. 
Highlights
Incremental sheets metal forming is a high flexible forming process, which can forming the sheets through the motion of non-traditional tool to manufacture the complicated products shapes, and the equipments of forming is appropriate for a wide variant products without expensive investments or matched tools through the movement of the tools onto certain tool path [1, 2]
This study focuses on the resultant residual stresses by forming variables, namely; using Taguchi method for the samples formed by (SPIF) single point incremental forming method
This technique depends on two groups; the first one is a special type of matrix called "orthogonal array (OA)" includes number of tests based on the number of levels for the controlling parameters, and the second one is (S/N) the signals to noise ratio
Summary
Incremental sheets metal forming is a high flexible forming process, which can forming the sheets through the motion of non-traditional tool to manufacture the complicated products shapes, and the equipments of forming is appropriate for a wide variant products without expensive investments or matched tools through the movement of the tools onto certain tool path [1, 2]. Operation variables were variants to find out their effect on residual stress values and distributions: diameter of tool (d), tool vertical step (Δz), and spindle speed (ω). Bogdan Chirita, et al (2014) [8]: studied the distribution of residual stresses through the part formed by (SPIF) operation as a work parameters function and to find out its influence on part quality using the same parameters above, it was found a favorable residual stress state and implying a suitable quality of the samples could be given using low diameter of the tool and step size as well, with higher values of spindle speed. This study focuses on the resultant residual stresses by forming variables, namely; (tool shape, step over, feed rates, and slope angle) using Taguchi method for the samples formed by (SPIF) single point incremental forming method. Using the (ANOVA) technique, the results have been examined and it showed that the tool diameter, step size, spindle speeds and feed rates contribute (4%, 57%, 10% and 29%) respectively, provide a higher wall angle of (55°)
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