Formability Analysis Of Aa6061 Aluminum Alloy Sheets In Single Point Incremental Forming

Abstract

Recently, Single Point Incremental Forming Has Caught The Devotion Of Automotive, Aerospace And Medical Industries As A Marginal To Conventional Stamping Process As An Economical Process Capable Of Manufacturing Sheet Metal Prototypes Bereft Of Expensive Dies. The First Objective Of The Study Was To Determine The Nature Of Maximum Wall Angles And Thinning Expected During The Single Point Incremental Forming Process On Aa6061 Aluminum Alloy With Different Thickness. The Second Objective Was To Study The Effect Of Different Process Parameters On The Maximum Wall Angle And Average Thinning. Thorough Experiments Were Accompanied Based On The Response Surface Method Approach For Input Process Parameters Namely; Step Depth (0.2mm, 0.5mm And 0.8mm), Tool Diameter (5mm, 10mm And 15mm), Feed Rate(1000mm/Min, 1500mm/Min And 2000mm/Min) And Material Thickness (0.8mm, 1.0mm And1.2mm). The Responses Of Formability Were Maximum Wall Angles And Thinning Measured For Different Process Parameters And Their Interactions (Step Depth, Tool Diameter, Feed Rate And Material Thickness). Based On The Numerical Simulation And Experimental Results, Several Conclusions Were Made On The Effects Of Process Parameters On The Maximum Wall Angle And Thinning. Analysis Of Variance (Anova) Was Used To Identify The Significant Control Factors And Their Interactions. From The Experimental Findings, An Attempt Was Made To Find The Optimal Combination Of The Process Parameters On The Basis Of A Proposed Predictive Mathematical Model. The Maximum Wall Angle Value Achieved Was 77.81??, With A 5mm Tool Diameter, Feed Rate Of 1000 Mm/Min, Step Depth Of 0.2 Mm And A Material Thickness Of 0.8mm And The Maximum Thinning Was 0.8563mm, With A 5mm Tool Diameter, Feed Rate Of 1000 Mm/Min, Step Depth Of 0.8Mm And A Material Thickness Of 1.2mm. Finally, The Study Proposed Guidelines For Forming Thick Sheets And Improving Formability And Production Rate Of Spif Process.