Title: Study of AA-1050 sheet metal parts processed by single point incremental forming with dummy sheet

Authors: Vikas Sisodia; Shailendra Kumar

Addresses: Department of Mechanical Engineering, Sardar Vallabhbhai National Institute of Technology, Surat 395007, Gujarat, India ' Department of Mechanical Engineering, Sardar Vallabhbhai National Institute of Technology, Surat 395007, Gujarat, India

Abstract: The present paper describes an experimental study of AA-1050 sheet metal part processed by single point incremental forming (SPIF) with dummy sheet. Influence of process parameters namely step-down size, tool size, feed rate, dummy sheet thickness and forming angle on surface roughness of formed part is investigated. From the analysis of results, it is observed that step-down size, tool size, dummy sheet thickness and forming angle are significant process parameter and feed rate is insignificant. Surface roughness decreases with increase in tool size, dummy sheet thickness and forming angle; while it increases with increase in step-down size. Based on experimentation and analysis of results, a mathematical model to predict surface roughness is developed. Further, optimisation is performed on the basis of desirability function to minimise surface roughness. Also, optimisation algorithm namely genetic algorithm and simulated annealing available in MATLAB optimisation tool box is applied to find out the optimum surface roughness. Experimental results are found to be in good agreement with results predicted by the developed mathematical model.

Keywords: single point incremental forming; SPIF; dummy sheet; tool size; surface roughness; optimisation.

DOI: 10.1504/IJMATEI.2020.106657

International Journal of Materials Engineering Innovation, 2020 Vol.11 No.2, pp.105 - 126

Received: 02 May 2019
Accepted: 25 Jun 2019
Published online: 16 Apr 2020 *

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