Formability and surface finish studies in single point incremental forming

A. Bhattacharya*, Samarjit Singh, K. Maneesh, N. Venkata Reddy, Jian Cao

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contribution

8 Scopus citations

Abstract

Incremental sheet metal forming (ISMF) has demonstrated its great potential to form complex three-dimensional parts without using a component specific tooling. The die-less nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet parts. However, ISMF has limitations with respect to maximum formable wall angle, geometrical accuracy and surface finish of the component. In the present work, an experimental study is carried out to study the effect of incremental sheet metal forming process variables on maximum formable angle and surface finish. Box-Behnken method is used to design the experiments for formability study and full factorial method is used for surface finish study. Analysis of experimental results indicates that formability in incremental forming decreases with increase in tool diameter. Formable angle first increases and then decreases with incremental depth and it is also observed that the variation in the formable angle is not significant in the range of incremental depths considered to produce good surface finishes during the present study. A simple analysis model is used to estimate the stress values during incremental sheet metal forming assuming that the deformation occurs predominantly under plane strain condition. A stress based criterion is used along with the above mentioned analysis to predict the formability in ISMF and its predictions are in very good agreement with the experimental results. Surface roughness decreases with increase in tool diameter for all incremental depths. Surface roughness increases first with increase in incremental depth up to certain angle and then decreases. Surface roughness value decreases with increase in wall angle.

Original languageEnglish (US)
Title of host publicationASME 2011 International Manufacturing Science and Engineering Conference, MSEC 2011
Pages621-627
Number of pages7
DOIs
StatePublished - Dec 5 2011
EventASME 2011 International Manufacturing Science and Engineering Conference, MSEC 2011 - Corvallis, OR, United States
Duration: Jun 13 2011Jun 17 2011

Publication series

NameASME 2011 International Manufacturing Science and Engineering Conference, MSEC 2011
Volume1

Other

OtherASME 2011 International Manufacturing Science and Engineering Conference, MSEC 2011
CountryUnited States
CityCorvallis, OR
Period6/13/116/17/11

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

Fingerprint Dive into the research topics of 'Formability and surface finish studies in single point incremental forming'. Together they form a unique fingerprint.

Cite this