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Influence of Single-Point Incremental Force Process Parameters on Forming Characteristics and Microstructure Evolution of AA-6061 Alloy Sheet

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Abstract

Single-point incremental forming (SPIF) process comprises a set of process variables, such as forming tool diameter, vertical pitch, spindle rotation speed, and tool velocity, which may affect the forming behavior of the sheet to be deformed. The objective of this work is to study the effect of SPIF process parameters on forming characteristics and microstructure development for the AA-6061 (T6) aluminum alloy sheet. The SPIF experiments and finite element (FE) simulations were performed at different process parameters to achieve conical shapes from the AA-6061 blanks. The effect of process parameters on forming forces, thickness uniformity in wall region of the cone and surface roughness of the blank was analyzed. A detailed microstructure study was performed to analyze the effect of process variables on microstructure and texture evolution during the SPIF process. This study reveals that the process parameters are likely to influence the texture development especially at high tool diameter and vertical pitch values. Therefore, suitability and consequences of using different combinations of tool diameter and vertical pitch values are discussed for AA-6061 alloy.

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Acknowledgments

The authors gratefully acknowledge the financial support provided for this work by the National Centre for Aerospace Innovation and Research, IIT Bombay, Powai, Mumbai, India.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Vivek Kumar Barnwal, Asim Tewari & Sushil K. Mishra

  2. National Centre for Aerospace Innovation and Research, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Vivek Kumar Barnwal & Asim Tewari

  3. Graduate Institute of Ferrous Technology, Pohang University of Science and Technology, 77 Cheongam-Ro, Nam-Gu, Pohang, 37673, South Korea

    Vivek Kumar Barnwal

  4. Department of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay, Powai, Mumbai, 400076, India

    Shanta Chakrabarty & K. Narasimhan

  5. School of Mechanical Engineering, Kalinga Institute of Industrial Technology, Bhubaneswar, Odisha, 751024, India

    Shanta Chakrabarty

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Barnwal, V.K., Chakrabarty, S., Tewari, A. et al. Influence of Single-Point Incremental Force Process Parameters on Forming Characteristics and Microstructure Evolution of AA-6061 Alloy Sheet. J. of Materi Eng and Perform 28, 7141–7154 (2019). https://doi.org/10.1007/s11665-019-04446-9

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