Lubricant Selection and Post Forming Material Characterization in Incremental Sheet Forming

Abstract

Single Point Incremental Forming (SPIF) is a flexible, novel and rapid sheet forming process to deform extra thin to the thick sheet with the help of computer numerical control unit, hemispherical tool and fixture. A tool follows a series of small incremental steps which deforms the sheet into the desired shape. Despite of recent development occurred in past, the little literature was reported which investigate the effect of various types of lubricants in SPIF process. This study aims to address the distinct type of lubricant to accomplish better surface roughness and formability of final parts while incremental forming of aluminium 5052 H32 sheets. After the forming process, the fractographies of the specimen were studied at optimal condition. The study is also extended to determine residual stresses generated due to incremental deformation and its effect on corrosion phenomenon with the environment. It has been found that the fracture zone material is likely to corrode more rapidly due to increased plastic deformation than the material at initial and middle forming zones.