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Experimental investigations and optimization of forming force in incremental sheet forming

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Abstract

Incremental sheet forming process has been proved to be quiet suitable and economical for job and batch type production, which exempts expensive and complex tooling for sheet forming. Investigation of forming forces becomes important for selecting the appropriate hardware and optimal process parameters in order to assure perfection and precision of process. Moreover, lack of available knowledge regarding the process parameters makes the process limited for industrial applications. This research paper aims at finding out effects of different input factors on forming forces in single-point incremental forming (SPIF) process. For operation sustainability and hardware safety, it becomes critical to optimize forming forces for a given set of factors to form a particular shape. In this study, optimization of input factors has been performed to produce conical frustums with helical tool path using Taguchi analysis as design of experiment (DOE) and analysis of variance (ANOVA). The optimal experimental conditions for forming forces have been calculated as sheet thickness (0.8 mm), step size (0.2 mm), tool diameter (7.52 mm), tool shape (hemispherical), spindle speed (1000 rpm), feed rate (1000 mm/min) and wall angle (50o). Effects of tool shape and viscosity of lubricants have also been investigated. An intensive understanding of the mechanism of forming forces has been presented, which shows that force trend after peak values depends upon instant input factors that can be categorized as a safe, severe and crucial set of parameters.

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Acknowledgement

The authors have no conflict of interest. The authors would like to thank ARK Mould & Tools Ltd., Gurgaon, and Nictech, Jaipur, for their assistance. The authors would also like to thank Mr Udayveer Singh, Mr Bissan Singh and Er. Sumit Nagar for their appreciable contribution in developing the experimental set-up.

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  1. Department of Mechanical Engineering, Guru Jambheshwar University of Science and Technology, Hisar, Haryana, 125001, India

    AJAY KUMAR & VISHAL GULATI

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  1. AJAY KUMAR
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  2. VISHAL GULATI
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Correspondence to AJAY KUMAR.

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KUMAR, A., GULATI, V. Experimental investigations and optimization of forming force in incremental sheet forming. Sādhanā 43, 159 (2018). https://doi.org/10.1007/s12046-018-0926-7

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  • DOI: https://doi.org/10.1007/s12046-018-0926-7

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