Experimental Investigation and Optimization of Incremental Sheet Metal Forming Process Parameters for Al6063 Alloy Using Computerized Numerically Control Machine

Abstract

Aa6063 Alloy Sheet Materials Are Widely Used In Various Industrial Products, Including Aerospace, Automotive, And Biomedical Applications. However, Recent Market Demands Have Shifted From Mass Production To Small Batch Production, Leading To The Need For Specialized Tools And Longer Lead Times. Single Point Incremental Forming (Spif) Sheet Metal Process Techniques Can Be Used To Form Various Sheet Metal Components In Small Batches And Prototypes At A Cheaper Cost Without The Need For Specialized Tooling. The Process Designer Can Alter Parameters Such As Step Size, Spindle Speed, Feed Rate, Tool Diameter, Lubrication, And Tool Shape. To Increase Spif Compatibility On An Industrial Scale, A Thorough Research On Process Parameters Has Been Conducted. The Taguchi-Based Experimental Investigation Was Designed To Optimize The Procedure For Forming Aa6063 Sheets. The Finalized L18 Orthogonal Array Has Six Parameters, With Six Levels. The Surface Roughness Value Of Produced Components Was Measured Using The Vogel Model Of Roughness Tester. The Experimental Inquiry Showed That Spindle Speed, Angle, Step Size, Feed Rate, And Tool Diameter Enhance Forming Hardness, While Increasing Lubricant Lowers It. Average Part Roughness Is Influenced By Lubrication, Feed, Step Size, And Angle, But Not By Speed Or Tool Diameter. This Work Sheds Light On How Spif Technology For Difficult-To-Form Materials Will Develop Going Forward. The Results From Confirmatory Trials At The Optimum Values Of Input Parameters Validate The Expected Outcomes Derived From Studying Responding Characteristics, Including Forming Force And Surface Roughness.