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

  • Lassaad Kilani
  • Tarek MabroukiEmail author
  • Mahfoudh Ayadi
  • Hechmi Chermiti
  • Salim Belhadi
ORIGINAL ARTICLE
  • 21 Downloads

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.

Keywords

Incremental forming ANOVA RSM Regression Optimization Design of experiments 

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)

Notes

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2020

Authors and Affiliations

  • Lassaad Kilani
    • 1
  • Tarek Mabrouki
    • 1
    Email author
  • Mahfoudh Ayadi
    • 1
    • 2
  • Hechmi Chermiti
    • 3
  • Salim Belhadi
    • 4
  1. 1.University of Tunis El Manar, ENIT, Applied Mechanics and Engineering Laboratory (LR-11-ES19)TunisTunisia
  2. 2.University of Carthage, ENIB, Campus Universitaire Menzel AbderrahmanTunisiaTunisia
  3. 3.University Campus Raccada, ISET de KairouanKairouanTunisia
  4. 4.University of Guelma, May 8th 1945 Mechanics and Structures Laboratory LMS)GuelmaAlgeria

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