Abstract
The surface finish is an important characteristic in the incremental sheet forming (ISF) process and is often influenced by numerous factors within the forming process. Therefore, this research was aimed at identifying the optimal forming parameters through the Taguchi method to produce high-quality formed products. The forming tool radius, spindle speed, vertical step increment, and feed rate were chosen as forming parameters in the experimental design, with surface roughness as the response variable. Taguchi L16 orthogonal array design and analysis of variance (ANOVA) test were used to identify the parameter’s optimal settings and examine the statistically significant parameters on the response, respectively. Results confirmed that a significant reduction in surface roughness occurred with a drop in vertical step size and an increase in feed rate. In detail, the vertical step size has the most significant influence on the surface roughness, followed by the feed rate and the forming tool radius. In conclusion, the optimum level settings were obtained: forming tool radius at level 3, spindle speed at level 1, vertical step size at level 1, and feed rate at level 4. Additionally, confirmation experiment results based on the optimal settings indicated a good agreement against the experimental observation. Further, the response surface methodology (RSM) was also exploited to devise a mathematical model for predicting the surface roughness. The results comparison confirmed that both techniques could effectively improvise the surface finish.
Highlights
Introduction published maps and institutional affilThe incremental sheet forming process (ISF) technique, known as dieless forming, is regarded as one of the flexible manufacturing technologies due to its ability to produce complicated components without using additional dies [1,2,3,4,5]
The statistical parameters of Equation (11), R2, adj.R2, and root mean square error (RMSE), were computed as 0.925, 0.812, and 0.0494, respectively. This outcome proves that the model reduction does not improve the model performance but somehow affects its prediction capability
Preliminary investigation results showed that better surface quality (Ra = 0.64 μm) was obtained using the combination of engine oil and grease lubricant, whereas low surface quality (Ra = 0.80 μm) was received from the engine oil lubricant
Summary
The material sheet used in this research is the AA3003-H18 aluminum alloy. The test samples were prepared at 0◦ , 45◦ , and 90◦ to the rolling directions to assess the AA3003-H18 Al alloy material properties such as Young’s modulus, tensile strength, yield strength, and percentage of total elongation. The average Young’s modulus of AA3003-H18 Al alloy material is estimated to be 69.58 MPa with the total average elongation of 5.46%. Limiting the forming depth to 37 mm is because of the sheet thickness and fracture experienced on the tested samples during the trial runs. The sheet blank dimension used in the single-point incremental forming process (SPIF) experiment is 280 × 320 mm with a thickness of 0.50 mm. A schematic representation of the SPIF process experimental setup is illustrated in Figure 1; as represented in Figure 1, it has the necessary equipment such as a position sensor, a hemispherical end forming tool, a blank holder, and an external die
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