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Effects of rolling ball tool parameters on roughness, sheet thinning, and forming force generated during SPIF process

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Abstract

Single-point incremental forming (SPIF) is a rising technology used shaping sheet-metals. The emergence of this manufacturing process is due to its capability to produce parts with complex shape at lower cost. The present contribution is focused on the presentation of a new designed rolling ball forming tool that can improve (SPIF) operations. For that, the effects of process working parameters on a set of process qualification criteria when forming of AA1050 aluminum alloy sheets is presented. Deep analyses treating impacts of tool step down, tool rolling ball diameter, and tool feed rate on the process responses such as forming axial forces, surface roughness, and sheet thinning are made. The analysis is based on statistical methodologies which made it possible to establish, using the multiple regression method, predictive analytical models for the different responses.

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Abbreviations

ANOVA:

Analysis of variance

D:

Rolling ball diameter (mm)

Df:

Degrees of freedom

F:

Tool feed rate (mm/min)

Favr :

Average axial forming force (N)

Fmax :

Maximal axial forming force (N)

Fz :

Axial Forming force (N)

F-value:

Fisher test value

ISF:

Incremental sheet forming

MS:

Mean squares

PC%:

Percentage of contribution (%)

P value:

Value of significance

RSM:

Response surface methodology

R2 :

Determination coefficient

R2adjusted :

Adjusted determination coefficient

R2predictif :

Predictive determination coefficient

Ra :

Arithmetic mean roughness (μm)

Rz :

Mean peak-to-valley height (μm)

Rt :

Maximum profile height (μm)

SPIF:

Single-point incremental forming

SS:

Squared deviations

SSD :

Sum of squared deviations

SST :

Total sum of squared deviations

ΔZ:

Vertical step down (mm)

ϕ:

Wall angle (degree)

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Authors and Affiliations

  1. University of Tunis El Manar, ENIT, Applied Mechanics and Engineering Laboratory (LR-11-ES19), P.O. Box 37, Le Belvédère, 1002, Tunis, Tunisia

    Lassaad Kilani, Tarek Mabrouki & Mahfoudh Ayadi

  2. University of Carthage, ENIB, Campus Universitaire Menzel Abderrahman, P.O. Box 66, Bizerte, 7035, Tunisia, Tunisia

    Mahfoudh Ayadi

  3. University Campus Raccada, ISET de Kairouan, 3199, Kairouan, Tunisia

    Hechmi Chermiti

  4. University of Guelma, May 8th 1945 Mechanics and Structures Laboratory LMS), P.O. Box 401, Guelma, 24000, Algeria

    Salim Belhadi

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  1. Lassaad Kilani
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  2. Tarek Mabrouki
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  3. Mahfoudh Ayadi
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  5. Salim Belhadi
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Correspondence to Tarek Mabrouki.

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Kilani, L., Mabrouki, T., Ayadi, M. et al. Effects of rolling ball tool parameters on roughness, sheet thinning, and forming force generated during SPIF process. Int J Adv Manuf Technol 106, 4123–4142 (2020). https://doi.org/10.1007/s00170-019-04918-1

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