Parameter Optimization in Incremental Forming of Titanium Alloy Material
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ORIGINAL ARTICLE
Parameter Optimization in Incremental Forming of Titanium Alloy Material C. Veera ajay1
Received: 30 January 2020 / Accepted: 14 July 2020 Ó The Indian Institute of Metals - IIM 2020
Abstract Incremental forming is a flexible and adaptable process with a high scope in future for prototyping sector and batch shop production. It finds application in almost every engineering field. One such prominent field is the research and development. The research and development are often associated with prototyping of a variety of products for evaluating and testing the design and clarifying production costs and issues. In this paper, experimentation of Ti-6Al-4V sheets using SPIF was studied, and the influence of tool feed (f), incremental step depth (d) and spindle speed (s) to the surface roughness (Ra), wall angle (h), and average thickness (t) were evaluated. The method was carried out using CNC Milling Machine with the help of a fixture and hemispherical end tool. Response surface methodology was used to design the experiments, and ANOVA was performed to find the factor which affected the selected method significantly. Finally, the input parameters were optimized to achieve maximum wall thickness, minimum surface roughness, and maximum wall angle. Keywords Sheet metal CNC machine tool CAD/CAM Response surface methodology ANOVA
& C. Veera ajay [email protected] 1
Department of Mechanical Engineering, National Engineering College, Kovilpatti, India
1 Introduction Incremental sheet forming (ISF) is a dieless sheet forming process which can reduce the high tooling cost associated with the traditional process and increase the customizability making it suitable for prototyping and in low volume production industries like aerospace, automotive, biomedical, etc. [1]. The incremental sheet forming process has better formability than other conventional sheet metal forming techniques due to localized deformations in ISF. Kopac and Kampus [2] used the ball-type forming tool with 10 mm diameter and used grease as lubricant which improved tribological characteristics. Park et al. [3] have compared the traditional sheet forming with the incremental sheet forming and have found that forming limit curve appears in a different pattern in ISF. The low step depth has increased the formability limit. Cerro et al. [4] used finite element analyses to predict accurately the response parameters such as geometrical accuracy, sheet thickness, and roughness of formed component. The FEA was carried out using ABAQUS explicit software, and results have been compared to the actual experimentation. The low incremental depth and application of lubricant between the contact surfaces have significantly improved the surface finish. Araghi et al. [5] combined the stretch forming process and incremental sheet metal forming process. The combined process has been observed to be similar to the two-point incremental forming. Sheet thinning in SPIF and combined process have been compared and studied in detail. Finite element simulat
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