Studies on single point incremental forming of Ti-6Al-4V alloy for aerospace applications

Abstract

Abstract Incremental Sheet metal forming (ISMF) is a novel approach in which forming of sheet metal is numerically controlled without the use of die, and the process has more scope in industry 4.0. The characteristics of ISMF reduce setup cost and unit cost by a great margin but it is suited only for batch/job production. In spite of the process capabilities, the process is still in research stage because of its limitations in part accuracy and product quality. This study involves experimentation of Ti-6Al-4V sheets using SPIF and understanding the influence of tool feed, incremental depth and spindle speed to the surface roughness, wall angle and thinning. The process is carried out by CNC Vertical Machining Center (VMC). For this work, the fixture and tool with hemispherical end used for forming is designed and fabricated. Optimization is carried out using Response surface methodology (Central Composite Design) to improve the process in terms of geometrical accuracy, surface finish and thinning. Experimental validation of optimal process parameters was found to be more accurate and thereby, the results will increase the application of the process in obtaining better product quality. The results indicated that the incremental depth have a major influence in determining the surface and formability characteristics of the formed material