scholarly journals Surface Finish Analysis in Single Point Incremental Sheet Forming of Rib-Stiffened 2024-T3 and 7075-T6 Alclad Aluminium Alloy Panels

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1640
Author(s):  
Tomasz Trzepieciński ◽  
Andrzej Kubit ◽  
Andrzej Dzierwa ◽  
Bogdan Krasowski ◽  
Wojciech Jurczak
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Rotational Speed ◽  
Single Point ◽  
Core Material ◽  
Tool Rotational Speed ◽  
Roughness Parameters ◽  
Step Size ◽  
Vertical Step

The article presents the results of the analysis of the interactions between the single point incremental forming (SPIF) process parameters and the main roughness parameters of stiffened ribs fabricated in Alclad aluminium alloy panels. EN AW-7075-T6 and EN AW-2024-T3 Alclad aluminium alloy sheets were used as the research material. Panels with longitudinal ribs were produced with different values of incremental vertical step size and tool rotational speed. Alclad is formed of high-purity aluminium surface layers metallurgically bonded to aluminium alloy core material. The quality of the surface roughness and unbroken Alclad are key problems in SPIF of Alclad sheets destined for aerospace applications. The interactions between the SPIF process parameters and the main roughness parameters of the stiffened ribs were determined. The influence of forming parameters on average roughness Sa and the 10-point peak–valley surface roughness Sz was determined using artificial neural networks. The greater the value of the incremental vertical step size, the more prominent the ridges found in the inner surface of stiffened ribs, especially in the case of both Alclad aluminium alloy sheets. The predictive models of ANNs for the Sa and the Sz were characterised by performance measures with R2 values lying between 0.657 and 0.979. A different character of change in surface roughness was found for sheets covered with and not covered with a soft layer of technically pure aluminium. In the case of Alclad sheets, increasing the value of the incremental vertical step size increases the value of the surface roughness parameters Sa and Sz. In the case of the sheets not covered by Alclad, reduction of the tool rotational speed increases the Sz parameter and decreases the Sa parameter. An obvious increase in the Sz parameter was observed with an increase in the incremental vertical step size.

scholarly journals Study of Friction and Wear Effects in Aluminum Parts Manufactured via Single Point Incremental Forming Process Using Petroleum and Vegetable Oil-Based Lubricants

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3973
Author(s):  
José M. Diabb Zavala ◽  
Oscar Martínez-Romero ◽  
Alex Elías-Zúñiga ◽  
Héctor Manuel Leija Gutiérrez ◽  
Alejandro Estrada-de la Vega ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Friction And Wear ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Forming Process ◽  
Step Size ◽  
Vertical Step ◽  
Stribeck Curves

This paper focuses on studying how mineral oil, sunflower, soybean, and corn lubricants influence friction and wear effects during the manufacturing of aluminum parts via the single point incremental forming (SPIF) process. To identify how friction, surface roughness, and wear change during the SPIF of aluminum parts, Stribeck curves were plotted as a function of the SPIF process parameters such as vertical step size, wall angle, and tool tip semi-spherical diameter. Furthermore, lubricant effects on the surface of the formed parts are examined by energy dispersive spectroscopy (EDS) and scanning electron microscope (SEM) images, the Alicona optical 3D measurement system, and Fourier-transform infrared spectroscopy (FTIR). Results show that during the SPIF process of the metallic specimens, soybean and corn oils attained the highest friction, along forces, roughness, and wear values. Based on the surface roughness measurements, it can be observed that soybean oil produces the worst surface roughness finish in the direction perpendicular to the tool passes (Ra =1.45 μm) considering a vertical step size of 0.25 mm with a 5 mm tool tip diameter. These findings are confirmed through plotting SPIFed Stribeck curves for the soybean and corn oils that show small hydrodynamic span regime changes for an increasing sample step-size forming process. This article elucidates the effects caused by mineral and vegetable oils on the surface of aluminum parts produced as a function of Single Point Incremental Sheet Forming process parameters.

Effect of Incremental Forming Process Parameters on Aluminum Alloy Using Experimental Studies

2015 ◽  
Vol 1119 ◽  
pp. 633-639 ◽  
Author(s):  
Sunil D. Majagi ◽  
G. Chandramohan ◽  
Mouleeswaran Senthil Kumar
Keyword(s):  
Aluminium Alloy ◽  
Process Parameters ◽  
Feed Rate ◽  
Rotational Speed ◽  
Incremental Sheet Forming ◽  
Thickness Reduction ◽  
Tool Rotational Speed ◽  
Forming Process ◽  
Vertical Step ◽  
Tool Diameter

Incremental Sheet Forming (ISF) process is Innovative and cost effective technology trend for forming products in manufacturing industries. The current research is to study and investigate the influence of incremental sheet forming process parameters on response surfaces of aluminium alloy sheet components. In this experiment, Aluminium alloy AA1050 sheet was selected to process forming by using CNC machining centre without expensive dies. Individual and interactive effect of different factors such as, thickness of sheet, tool diameter, vertical step, feed rate, and tool rotational speed at different levels were assessed to improve the processing time. For the design of experiment (DOE), Taguchi’s L27 orthogonal array was used to investigate and optimize the influencing ISF process parameters. From ANOVA results, it was found that for thickness reduction, the influencing factors were as following; feed rate (21.40 %); for roughness, tool rotation speed (20.43 %) and for hardness, thicknesses of sheet (39.49 %). Response Surface Methodology (RSM) showed that optimal values obtained were 0.46 mm, 10 mm, 0.6818 mm, 2232.32 mm/min., and 2626 rpm for thickness of sheet, tool diameter, vertical step, feed rate and tool rotational speed respectively. For percentage thickness reduction of 59.6%, minimum roughness 2.09μm, and maximum hardness 41.7 BHN, the confirmatory test showed values of 64.78 % thickness reduction, roughness of 2.14μm and hardness of 44.82 BHN that were in agreement with the predicted value.

The Effected of Single Point Incremental Forming Process Parameters on the Formed Part Surface Roughness

2014 ◽  
Vol 979 ◽  
pp. 335-338
Author(s):  
Kittiphat Rattanachan ◽  
Chatchapol Chungchoo
Keyword(s):  
Surface Roughness ◽  
Sheet Metal ◽  
Process Parameters ◽  
Feed Rate ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Tool Rotational Speed ◽  
Forming Process ◽  
Inner Surface

The single point incremental forming process (SPIF) are suited for sheet metal prototyping, because it is a low cost production process that produces sheet metal part without any used of die, and easy to adjust the part’s geometry by change toolpath. But the quality of forming parts is still in doubt. In some applications, such as mould cavity for rapid mould and the medical parts, in this case the inside surface roughness plays an importance role. In this paper, the SPIF process parameters that affected to the inner surface roughness were experimental studied. The investigated parameters are composing of tool feed rate, side overlap, depth step and tool radius. The 2k-p factorial experimental design was used to analyze the interaction between each parameter. The results showed that increasing feed rate and depth step decreased inner surface roughness. Reducing tool rotational speed and feed rate reduced inner surface roughness. So increasing depth step with decreasing side overlap reduced inner surface roughness. The large tool radius and lower side overlap improved inner surface roughness. The large tool radius and higher depth step improved inner surface roughness. And last, reducing tool rotational speed with larger tool radius, the inner surface roughness is decreased.

Force Measurements for Single Point Incremental Forming: An Experimental Study

2005 ◽  
Vol 6-8 ◽  
pp. 441-448 ◽  
Author(s):  
Joost R. Duflou ◽  
Alexander Szekeres ◽  
P. Vanherck
Keyword(s):  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Force Measurements ◽  
Test Program ◽  
Forming Process ◽  
Step Size ◽  
Experimental Platform ◽  
Vertical Step ◽  
The Relationship

In this paper an experimental platform capable of measuring forces in process during an incremental forming procedure is described and the results garnered from it are presented. Some of the earliest measurements of forces in incremental forming and the changes induced on the measured load are reported. Using a table type force dynamometer with incremental forming fixture mounted on top, three components of force were measured throughout the forming process. They were found to vary as the parts were made. The reported experimental test program was focused on the influence of three different process parameters on the forming forces: the vertical step size between consecutive contours, the diameter of the tool and the steepness of the part’s wall. For the tested material, analytical results demonstrating the relationship between the respective process parameters and the induced forces are presented in this paper.

Evaluation of Process Parameters in Machining of AA6063 Alloy

2018 ◽  
Vol 1148 ◽  
pp. 109-114
Author(s):  
M. Balaji ◽  
C.H. Nagaraju ◽  
V.U.S. Vara Prasad ◽  
R. Kalyani ◽  
B. Avinash
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Process Parameters ◽  
Single Channel ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Aa6063 Alloy

The main aim of this work is to analyse the significance of cutting parameters on surface roughness and spindle vibrations while machining the AA6063 alloy. The turning experiments were carried out on a CNC lathe with a constant spindle speed of 1000rpm using carbide tool inserts coated with Tic. The cutting speed, feed rate and depth of cut are chosen as process parameters whose values are varied in between 73.51m/min to 94.24m/min, 0.02 to 0.04 mm/rev and 0.25 to 0.45 mm respectively. For each experiment, the surface roughness parameters and the amplitude plots have been noted for analysis. The output data include surface roughness parameters (Ra,Rq,Rz) measured using Talysurf and vibration parameter as vibration amplitude (mm/sec) at the front end of the spindle in transverse direction using single channel spectrum analyzer (FFT).With the collected data Regression analysis is also performed for finding the optimum parameters. The results show that significant variation of surface irregularities and vibration amplitudes were observed with cutting speed and feed. The optimum cutting speed and feed from the regression analysis were 77.0697m/min and 0.0253mm/rev. for the minimum output parameters. No significant effect of depth of cut on output parameters is identified.

scholarly journals ANALYSIS OF THE SURFACE QUALITY OF PARTS PROCESSED BY SINGLE POINT INCREMENTAL FORMING

2016 ◽  
Vol 19 (3) ◽  
Author(s):  
CRINA RADU ◽  
EUGEN HERGHELEGIU ◽  
ION CRISTEA ◽  
CAROL SCHNAKOVSZKY
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Incremental Forming ◽  
Single Point ◽  
Single Point Incremental Forming ◽  
Metal Sheets ◽  
Vertical Step ◽  
Tool Diameter ◽  
Aluminium Metal

<p>The aim of the current work was to analyse the influence of the process parameters (tool diameter, size of the vertical step of tool, feed rate and spindle speed) on the quality of the processed surface, expressed in terms of roughness and macrostructure in the case of parts processed by single point incremental forming. The analysis was made on A1050 aluminium metal sheets. The obtained results revealed that the process parameters influence differently the surface quality, the worst influence being exerted by the increase of the vertical step of tool. </p>

Parameter optimization and texture evolution in single point incremental sheet forming process

2019 ◽  
Vol 234 (1-2) ◽  
pp. 126-139 ◽  
Author(s):  
Shamik Basak ◽  
K Sajun Prasad ◽  
Amarjeet Mehto ◽  
Joy Bagchi ◽  
Y Shiva Ganesh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Regression Models ◽  
Incremental Forming ◽  
Single Point ◽  
Sheet Forming ◽  
Incremental Sheet Forming ◽  
Single Point Incremental Forming ◽  
Input Process ◽  
Truncated Cone

Prototyping through incremental sheet forming is emerging as a latest trend in the manufacturing industries for fabricating personalized components according to customer requirement. In this study, a laboratory scale single-point incremental forming test setup was designed and fabricated to deform AA6061 sheet metal plastically. In addition, response surface methodology with Box–Behnken design technique was used to establish different regression models correlating input process parameters with mechanical responses such as angle of failure, part depth per unit time and surface roughness. Correspondingly, the regression models were implemented to optimize the input process parameters, and the predicted responses were successfully validated at the optimal conditions. It was observed that the predicted absolute error for angle of failure, part depth per unit time and surface roughness responses was approximately 0.9%, 4.4% and 6.3%, respectively, for the optimum parametric combination. Furthermore, the post-deformation responses from an optimized single point incremental forming truncated cone were correlated with microstructural evolution. It was observed that the peak hardness and highest areal surface roughness of 158 ± 9 HV and 1.943 μm, respectively, were found near to the pole of single-point incremental forming truncated cone, and the highest major plastic strain at this region was 0.80. During incremental forming, a significant increase in microhardness occurred due to grain refinement, whereas a substantial increase in the Brass and S texture component was responsible for the increase in the surface roughness.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

Parameters optimization in FSW of polypropylene based on RSM

2015 ◽  
Vol 11 (1) ◽  
pp. 32-42 ◽  
Author(s):  
K Panneerselvam ◽  
Kasirajan Lenin
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Optimization Techniques ◽  
Parameters Optimization ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Output Characteristics ◽  
Tool Pin

Purpose – The purpose of this paper is to weld polypropylene (PP) material by friction stir welding (FSW) process. The input process parameters considered were: tool pin profile, feed rate and tool rotational speed and the process output characteristics were tensile strength, Shore-D hardness, Rockwell hardness, Izod strength, Charpy strength and nugget area. Design/methodology/approach – Optimization of process parameters were carried out based on response surface methodology (RSM) and significant parameters were obtained by performing analysis of variance (ANOVA). Findings – The optimized results were the threaded pin profile for feed of 60 mm/min and tool rotational speed of 1,500 rpm. A confirmation test was carried out to verify the optimized results. Originality/value – In this paper, the process parameters were optimized based on RSM. This is newly adopted optimization techniques in the FSW process of PP materials and also it gives better results.

scholarly journals The influence of vibrations on surface roughness formed during precision boring

2017 ◽  
Vol 37 (1) ◽  
pp. 1-5
Author(s):  
Dariusz Korzeniewski ◽  
Natalia Znojkiewicz
Keyword(s):  
Surface Roughness ◽  
Rotational Speed ◽  
Piezoelectric Sensor ◽  
Stability Loss ◽  
Vibration Level ◽  
Roughness Parameters ◽  
Machined Surface ◽  
Boring Tool ◽  
Machined Surface Roughness ◽  
Conventional Tool

AbstractIn this paper, the analysis of vibrations on surface roughness generated during boring with the application of the conventional boring tool and one with the damper is presented. The experiments included the measurement of vibration accelerations carried out with the piezoelectric sensor, as well as the evaluation of surface roughness parameters after each machining pass. The obtained results reveal that in the investigated range, no stability loss was found. Furthermore, the growth of the rotational speed induces the increase of vibration level, as well as the growth of the differences between the vibration values generated during boring with the conventional tool and one equipped with damper. Vibrations have also the direct influence on the machined surface roughness. In case of the tool equipped with the damper, the tool’s overhang L had more intense influence than rotational speed n. However, for the conventional boring tool this dependency was unequivocal.

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