Tool wear in the single point incremental forming

Abstract

The single point incremental forming (SPIF) is an immerging forming technique in which the metal sheets are shaped to a simple tool rather than the dedicated dies. The SPIF is more suitable for the formation of customized products, models, rapid prototyping, and low batch production. Forming tool and its life plays a vital role in manufacturing processing and it is directly related to productivity and production rate. The present study is concentrated on the tool wear measurement in the SPIF in which, 440C steel is utilized as forming tool and aluminum grade AA3003-O (annealed) sheet are taken as work. Further, a model is utilized for the prediction of wear and compared to measured tool wear. The measured and predicted tool wear is in the range of 0.0199 mm to 0.0379 mm and 0.0174 mm to 0.0439 mm respectively with the maximum error of 0.0330 mm in trail run 03. The overall coefficient of performance (R2) of the developed model is reported as 0.95149 and means absolute error (MAE) of −0.0048 mm.