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Response surface analysis of cold formability of polymers in Incremental Sheet Forming: Effect of parameters and associated thermal softening

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Abstract

The response surface approach was employed to analyze the influence of process parameters and associated thermal softening on the cold formability of two polymers, namely PVC and PE, in ISF. Three process parameters namely r/to, r/p and ω/f were varied over wide ranges. To know the effect of temperature variations on the ductility of material, thermal softening index was defined as ΔT/mp (ΔT is rise in temperature and mp is melting point of material). The magnitude of this index increased with the increase in the value of considered parameters. Further, for given set of parameters, its value was low for PVC and high for PE. Regarding its influence on forming, it was observed to significantly affect the formability and type of failure. For PVC, the formability increased with an increase in its value; however, for PE, the formability contrarily reduced. Moreover, the failure in the former material (low index and high strength) occurred due to fracture and in the latter (high index and low strength) took place due to wrinkling. These findings led to conclude to attain low softening index for maximizing the formability of soft polymers (say PE) and high index for the high strength polymers (say PVC).

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Abbreviations

r :

tool radius

t o :

sheet thickness

t :

wall thickness

p :

step size

f :

feed

ω :

rotational speed

θ :

wall angle

ΔT :

rise in temperature during forming

mp :

melting point

ISF :

Incremental sheet forming

PVC :

Polyvinyl Chloride

PE :

Polyethylene

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, GIK Institute of Engineering, Sciences & Technology, Topi, Swabi, KP, Pakistan

    Ghulam Hussain

  2. Department of Mechanical Engineering, Eastern Mediterranean University, Gazimagusa, TRNC Via Mersin-10, Turkey

    Aminreza Mahna

  3. Department of Industrial Engineering, King Abdulaziz University, Jeddah, Kingdom of Saudi Arabia

    Asif Iqbal

Authors
  1. Ghulam Hussain
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  2. Aminreza Mahna
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  3. Asif Iqbal
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Correspondence to Ghulam Hussain.

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Hussain, G., Mahna, A. & Iqbal, A. Response surface analysis of cold formability of polymers in Incremental Sheet Forming: Effect of parameters and associated thermal softening. Int. J. Precis. Eng. Manuf. 17, 613–621 (2016). https://doi.org/10.1007/s12541-016-0074-0

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  • DOI: https://doi.org/10.1007/s12541-016-0074-0

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