The Optimization of Sheet Forming on Residual Stress and Surface Roughness with Two Point Incremental Forming Process (TPIF) of Aluminum Alloy Parts

Abstract

This study investigates the residual stress and surface roughness of AA5052 aluminum alloy with two points incremental forming (TPIF) processed. The experimental tool used for forming was a ball-shape tool for the truncated cone geometry of workpieces and forming by CNC machines. The residual stress was measured using the experimental forming tool. The residual stress was measured using the X-ray diffraction method. This study aimed to optimize the parameters using the Taguchi and analysis of variance (ANOVA) techniques. The TPIF process parameters include tool rotation speed and incremental depth. The results revealed that the optimal parameter obtained for the lowest residual stress and surface roughness were A1B1 (Rotation speed 0 rpm and Incremental depth 0.3 mm) with residual stress of 21.14 MPa and 0.46 μm of surface roughness. According to the results obtained by ANOVA, it was found that the rotation speed was significant to residual stress and incremental depth insignificant to residual stress. On the other hand, the most significant factor for surface roughness was incremental depth, but rotation speed was insignificant to surface roughness of formed parts at 95% confidence level.