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Parametric Optimization on Single Point Incremental Forming of Aluminum Alloy AA 2219-O using Response Surface Methodology

  • Research Article-Mechanical Engineering
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Abstract

Single Point Incremental Forming (SPIF) is an emerging sheet metal forming process which has been used in the prototype production of complex geometries. The geometric inaccuracies and quality of formed parts are the major obstructions in commercialization of SPIF process. The aim of presented work is to study this hindrance using experimental and numerical investigation on Aluminum Alloy 2210-O. Parametric optimization is done using Response Surface Methodology (RSM) for quality factor (surface roughness) and geometric accuracy (Maximum wall angle) while minimizing thickness reduction and forming time. For this purpose, three experimental setups were designed in this study, using tool types and tool paths. During investigation, the interaction and main effects of process parameters, viz. feed rate, spindle speed, and step increment are evaluated on surface roughness (Ra), maximum wall angle \(({\alpha }_{\mathrm{max}})\), % thickness reduction (% TR), and forming time (T) using ANOVA method. Results showed that among all the parameters of SPIF process, step increment is the most significant parameter for both forming paths using ball end and flat end tool. The comparative analysis of this study suggested that the ball end tool using the bidirectional path was better than the other setups. Furthermore, the results revealed that the ball end tool using a spiral path was better in desirability achievement (73%) as compared to the flat end tool using a spiral path (71.2%). The findings of this study are beneficial in paving a path for optimization of the SPIF process for an industrial-scale production of Al alloy AA 2219-O with desired characteristics.

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Availability of data and material

The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Funding

This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

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Authors and Affiliations

  1. Industrial Engineering Department, University of Engineering and Technology, Taxila, 47080, Pakistan

    Umair Khalil & Summyia Qamar

  2. Mechanical Engineering Department, College of Engineering and Technology, University of Sargodha, Sargodha, Pakistan

    Muhammad Haris Aziz

  3. School of Engineering, RMIT University Bundoora East Campus, Mill Park, Victoria, 3083, Australia

    Khurram Munir

Authors
  1. Umair Khalil
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  2. Muhammad Haris Aziz
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  3. Summyia Qamar
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  4. Khurram Munir
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Contributions

UK was involved in methodology, resources collection, investigation, data curation and formal analysis. MHA was involved in conceptualization, supervision and project administration. SQ was involved in software, writing—original draft and visualization. KM was involved in validation and writing—review and editing.

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Correspondence to Muhammad Haris Aziz.

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The authors have no conflict of interests. The authors also state that they have full control of all primary data and that they agree to allow the journal to review their data if requested.

Appendix

Appendix

See Tables

Table 7 DOE and corresponding responses for a rotating tool and spiral path
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7 and

Table 8 DOE and corresponding responses for a flat end tool and bi-directional path
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8

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Khalil, U., Aziz, M.H., Qamar, S. et al. Parametric Optimization on Single Point Incremental Forming of Aluminum Alloy AA 2219-O using Response Surface Methodology. Arab J Sci Eng 48, 4025–4044 (2023). https://doi.org/10.1007/s13369-022-07333-z

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  • DOI: https://doi.org/10.1007/s13369-022-07333-z

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