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Numerical Modeling and Optimization with Novel Process Parameters in the Incremental Forming of DC04 Sheets

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Abstract

There is an increasingly challenging need for the production of agile manufacturing methods that can easily be adapted to the relentless launch of new products in the market. A single point incremental sheet forming (SPIF) is a novel approach for rapid prototyping and small-batch sheet metal part manufacture. A small-sized tool deforms the clamped blank incrementally through a prescribed tool path, despite being low-cost consuming compared to traditional forming techniques. The incremental forming method is not commonly employed due to excessive surface roughness, uneven sheet thickness distribution, and springback. The investigation has been made to commercialize this technology on the shop floor through rapid prototyping and new product development. An attempt was made to evaluate the influence of process parameters like dummy sheet thickness, the number of cut-out blanks, and wall angle on the final sheet thickness, forming forces, and springback by applying the finite element method. It has been observed that the wall angle is found to be the most effective parameter affecting the final sheet thickness, forming force, and springback in SPIF, followed by dummy sheet thickness and the number of cut-out blanks. In the current investigations, initially, a FE analysis was performed to examine the influence of new process parameters on SPIF performance using a well-designed statistical tool. Later, ANOVA was employed to study the effect of all the individual effects on process performance. In order to reach a generalized conclusion, the study has to be made on a variety of materials (polymer, composite, and metal) and shapes to evaluate the exact effect of parameters on the SPIF process performance in real-time applications.

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Acknowledgment

The authors acknowledge the Science and Engineering Research Board, Department of Science and Technology, India, for funding the present research work [Grant Number SRG/2020/001355]

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  1. Department of Mechanical Engineering, Sardar Vallabhbhai National Institute of Technology, Surat, Gujarat, India

    Amrut Mulay, Hiral Hirani & Sudarshan Kumar Choudhary

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  1. Amrut Mulay
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  2. Hiral Hirani
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  3. Sudarshan Kumar Choudhary
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Correspondence to Amrut Mulay.

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Mulay, A., Hirani, H. & Choudhary, S.K. Numerical Modeling and Optimization with Novel Process Parameters in the Incremental Forming of DC04 Sheets. J. of Materi Eng and Perform 32, 2344–2355 (2023). https://doi.org/10.1007/s11665-022-07263-9

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  • DOI: https://doi.org/10.1007/s11665-022-07263-9

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