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Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments

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Abstract

Single point incremental forming (SPIF) is a sheet metal forming process used to obtain customized products with complex shapes. A hemispherical tool producing a series of local plastic deformations leads to increase in the formability of the final product. However, this forming technology still carries some drawbacks. The investigation of SPIF in terms of quality production and process optimization has always been a challenge to the researchers. An attempt has been made to study the effect of SPIF process parameters such as feed rate (f), step depth (p), tool diameter (d) and sheet thickness (t i) on surface roughness (R a) and maximum forming angle (Ø max) while forming of high strength AA5052-H32 alloy sheet. Response surface methodology (RSM) with the Box–Behnken design is used to develop a mathematical model in terms of the above parameters. An analysis of variance (ANOVA) test shows that step depth, tool diameter has a significant effect on the surface roughness and formability (P < 0.0001). The average surface roughness is found to increase with an increase in step depth and decrease in tool diameter, whereas the maximum forming angle is found to decrease with increase in step depth and tool diameter. The confirmation experiments are performed to check the adequacy of the proposed model.

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Acknowledgements

The authors are thankful to MSME’s authorities Mr. Hemant Kapse, Managing Director, and Mr. Jayesh Bagul, Design Manager, Indo-German Tool Room, Aurangabad for providing the facility to carry out research work. Further, Department of Mechanical Engineering, National Institute of Technology, Warangal for its continuous support towards carrying out research work and resolving necessary financial issues under Ministry of Human Resource Development, Government of India. The authors are also like to express their sincere thanks to Dr. Vijay Gadakh, Associate Professor, AVCOE, Sangamner, India.

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Authors and Affiliations

  1. Mechanical Engineering Department, National Institute of Technology, Warangal, 506004, India

    Amrut Mulay, Satish Ben & Syed Ismail

  2. Faculty of Production Engineering, Warsaw University of Technology, Narbutta 85, Warsaw, Poland

    Amrut Mulay & Andrzej Kocanda

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  1. Amrut Mulay
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  2. Satish Ben
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  3. Syed Ismail
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  4. Andrzej Kocanda
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Correspondence to Satish Ben.

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Technical Editor: Márcio Bacci da Silva.

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Mulay, A., Ben, S., Ismail, S. et al. Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments. J Braz. Soc. Mech. Sci. Eng. 39, 3997–4010 (2017). https://doi.org/10.1007/s40430-016-0703-7

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  • DOI: https://doi.org/10.1007/s40430-016-0703-7

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