Investigation The Effects Of Process Parameters On Single Point Incremental Forming Processes On Aluminum (1050) Sheet

Abstract

Now Day There Is An Increasing Demand In Metal Forming Processes In Which One Is Sheet Metal Forming Process For Lots Of Applications. Sheet Metal Forming Have Many Processes Out Of These Incremental Forming Is An Emerging Technology, In Which Forming Was Done By Cnc (Computer Numeric Control) Milling Machine. So That The Forming Process Was Step By Step Gradual Forming Process. Unlike To Two The Point Forming Process And Spinning Processes Single Point Incremental Forming Process Is Die-Less In Nature. Incremental Forming Provides Competitive Alternative For Economically And Also Effective In Fabricating Low Volume Products Even Has Important Too In Mold Making And Pattern. This Process Locally Deforms Sheet Metal Using A Moving Spherical Tool Head And The Shape Is Governed By The Path Of The Tool. The Objective Of This Thesis Is To Study On Truncated Pyramid Of Products By Maintaining Its Formability Avoiding Cracking And The Optimum Forming Condition Through Simulation And Modeling. Methodology Aspect Was Done Using Master Cam For Generating The Tool Path And The Modeling Was Done By Solid Work Software. Once Tool Movement Was Created Using Software Master Cam X5 Which Simulate The Path Of The Tool And Generate A Code Command Which Can Understand In The Cnc Three-Axis Milling. The Formability Was Analyzed By Using Finite Element Software Abaqus 6.13. The Simulations Were Performed On Different Parameters Like Sheet Thickness, Tool Diameter, Step Depth, Spindle Rotational Speed. From Simulation Result Of We Obtain Equivalent Von Misses Stress And Equivalent Plastic Strain. We Compare The Result With Other Processes And Compare With The Ultimate Stress Value Of Aluminum (1050). Strain Distribution Across The Mid-Section And Edge Section On The Deformed Sheet From Each Experiment We Conduct. The Blank Material Used In The Forming Process Is Aluminum (Aa1050) And Steel (1040) For Tooling. The Product Produced Is Truncated Pyramid Having Dimension Having Square Base Of Side Of 200mm With Depth Up To 4cm And Having Fillet At Corner. After Completing This Thesis, It Identified Parameters Affecting The Process And Optimize The Parameter For Better Forming Process.