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Effects of process parameters on thickness thinning and mechanical properties of the formed parts in incremental sheet forming

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Abstract

Incremental sheet forming (ISF) is a promising method for forming metal sheets, by which parts can be manufactured without the use of dedicated dies. However, the process has not been widely used for industrial application due to the unsatisfactory service performance of the formed parts. This paper focuses on improving the thickness distribution and mechanical properties (e.g., hardness, yield strength, and tensile strength) through process optimization. The response surface methodology with a Box-Behnken design is used to investigate how different process parameters affect the thickness thinning and mechanical properties. A set of experiments with 15 tests for pyramid-forming process is performed, and three parameters including step-down size, sheet thickness, and tool diameter are considered. The results show that the maximum thinning rate is lower with larger step-down size and larger tools. In addition, compared with the initial sheet, the values of hardness, yield strength, and tensile strength have been increased considerably due to the strain hardening. The present work provides useful guidance in improving the product quality formed by incremental sheet forming.

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Funding

This study is financially supported by the National Natural Science Foundation of China (51605258), China Postdoctoral Science Foundation funded project (2016M592180), Postdoctoral innovation project of Shandong Province (201701011), and State Key Laboratory of High Performance Complex Manufacturing, Central South University (Kfkt2017-04).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, No.17923, Jingshi Rd, Jinan, 250061, China

    Yanle Li, Xiaoxiao Chen, Weidong Zhai, Liming Wang & Jianfeng Li

  2. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha, 410083, China

    Yanle Li

  3. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Yanle Li, Liming Wang & Jianfeng Li

  4. School of Material Science & Engineering, Shandong University, Jinan, 250061, China

    Zhao Guoqun

Authors
  1. Yanle Li
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  2. Xiaoxiao Chen
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  3. Weidong Zhai
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  4. Liming Wang
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  5. Jianfeng Li
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  6. Zhao Guoqun
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Corresponding author

Correspondence to Liming Wang.

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Li, Y., Chen, X., Zhai, W. et al. Effects of process parameters on thickness thinning and mechanical properties of the formed parts in incremental sheet forming. Int J Adv Manuf Technol 98, 3071–3080 (2018). https://doi.org/10.1007/s00170-018-2469-9

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  • DOI: https://doi.org/10.1007/s00170-018-2469-9

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