Multi-Response Optimization of Process Parameters to Minimize Geometric Inaccuracies in the Single Point Incremental Forming Process

Abstract

The incremental sheet metal forming (ISMF) process has been one of the developments in the field of conventional sheet metal forming processes and is normally ideal for making customized parts. The formation of components without component-specific dies/tools in ISMF provides a competitive alternative for producing low-volume sheet metal components economically and efficiently. Single point incremental forming (SPIF) is a solely die-less process and simple version of ISMF technology for manufacturing sheet material components. In this chapter, average radial error (mm), springback (°), and pillow effect (mm) have been considered as main discrepancies that occurred in part formed by the SPIF process. A comparison between ideal CAD geometry and the formed part was made to predict the geometrical errors. Taguchi method-based design of experiments, the L16 orthogonal array, was employed to carry out the experiments on the developed SPIF setup. The process parameters were optimized for better responses based on the acquired results, as explained in the chapter. Multi-response optimization based on utility theory and the Taguchi method was utilized. The unified response consisting of three response parameters was expressed as a common index (utility) and studied for the optimal setting using the Taguchi approach.