Exploration of Appropriate Tool Material and Lubricant for Elevated Temperature Incremental Forming of Aluminium Alloy
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International Journal of Precision Engineering and Manufacturing https://doi.org/10.1007/s12541-020-00447-0
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Exploration of Appropriate Tool Material and Lubricant for Elevated Temperature Incremental Forming of Aluminium Alloy Swarit Anand Singh1 · Satwik Priyadarshi1 · Puneet Tandon1 Received: 11 February 2020 / Revised: 19 October 2020 / Accepted: 24 November 2020 © Korean Society for Precision Engineering 2020
Abstract In metal forming processes, the material of forming tools and lubricants play a very important role. It not only influences the forming process but also affects the surface finish of the produced product. Moreover, the product cost is directly associated with the cost of tools and lubricants. The present research explores appropriate tool materials and suitable lubricants to be used in Elevated Temperature Incremental Forming (ET-IF) of Aluminium alloy for efficient results. For the purpose, tool materials and lubricants used in Incremental Forming processes at higher temperatures were identified from the literature. The physical and chemical properties of the reported tool materials and lubricants, along with the established applications, were studied. Besides, the availability and cost of the lubricants, as well as machinability of the tool materials, were also considered to identify a set of feasible tool materials and lubricants for possible ET-IF applications. Subsequently, experiments were carried out with the identified set of tool materials and lubricants. Based on the observations made and the experimental results, different tool materials and lubricants were evaluated. The work recommends Tool steel (EN-31) and Molybdenum disulfide mixture as the most appropriate tool material and lubricant, respectively. Keywords Elevated temperature incremental forming · Aluminium alloy · Tool materials · Lubricants
1 Introduction Of late, the manufacturing research community is giving high emphasis on the advances in forming technologies. Incremental Forming (IF) is one such promising technology, which can be used to produce user-specific products in low volume productions. IF process does not require any partspecific tooling; hence, the product formed is not expensive. Further, as the IF process plan is developed with the help of digital technologies, thus, with a single tool, just by changing the Computer Numeric Control (CNC) program, a different type of geometry can be formed. The outer boundary of the sheet is clamped, and the tool moves over it by gradually applying load in the downward (or upward) direction. This causes local deformation of the sheet, and the required geometry is formed [1, 2]. However, the materials which are challenging to form at room temperature using the IF * Puneet Tandon [email protected] 1
deLOGIC Lab, Mechanical Engineering Discipline, PDPM Indian Institute of Information Technology, Design and Manufacturing, Jabalpur 482005, India
process may be formed at higher temperatures. Such technology is known as Elevated Temperature Incremental Form
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