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Comparison of plastic strains on AA5052 by single point incremental forming process using digital image processing

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Abstract

In this study, a surface based strain measurement was used to determine the formability of the sheet metal. A strain measurement may employ manual calculation of plastic strains based on the reference circle and the deformed circle. The manual calculation method has a greater margin of error in the practical applications. In this paper, an attempt has been made to compare the formability by implementing three different theoretical approaches: Namely conventional method, least square method and digital based strain measurements. As the sheet metal was formed by a single point incremental process the etched circles get deformed into elliptical shapes approximately, image acquisition has been done before and after forming. The plastic strains of the deformed circle grids are calculated based on the nondeformed reference. The coordinates of the deformed circles are measured by various image processing steps. Finally the strains obtained from the deformed circle are used to plot the forming limit diagram. To evaluate the accuracy of the system, the conventional, least square and digital based method of prediction of the forming limit diagram was compared. Conventional method and least square method have marginal error when compared with digital based processing method. Measurement of strain based on image processing agrees well and can be used to improve the accuracy and to reduce the measurement error in prediction of forming limit diagram.

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Authors and Affiliations

  1. Department of Production Technology, MIT Campus, Anna University, Chennai, Tamilnadu, 600 044, India

    V. Mugendiran

  2. Department of Industrial Engineering, CEG Campus, Anna University, Chennai, Tamilnadu, 600 025, India

    A. Gnanavelbabu

Authors
  1. V. Mugendiran
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  2. A. Gnanavelbabu
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Corresponding author

Correspondence to A. Gnanavelbabu.

Additional information

Recommended by Associate Editor Dae-Cheol Ko

V. Mugendiran is currently working as an Assistant Professor, Department of Production Technology in Anna University Chennai. He received his B.E., Mechanical Engineering from University of Madras, and M.E., CAD/CAM from Anna University, India. He is currently doing his Ph.D., in the area of metal forming. His research areas are Metal forming, Finite Element Analysis and Image Processing.

A. Gnanavelbabu received B.E. degree in Mechanical Engineering from University of Madras, India. He received his Post Graduate and Doctoral Degrees from Department of Production Engineering, National Institute of Technology, Trichy. He is currently working as an Associate Professor, Department of Industrial Engineering in Anna University Chennai. His research areas are Tribology of advanced materials, Composites, Computational Intelligence, Lean Sigma and Supply Chain Management.

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Mugendiran, V., Gnanavelbabu, A. Comparison of plastic strains on AA5052 by single point incremental forming process using digital image processing. J Mech Sci Technol 31, 2943–2949 (2017). https://doi.org/10.1007/s12206-017-0537-y

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  • DOI: https://doi.org/10.1007/s12206-017-0537-y

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