Single-point incremental forming is a novel and flexible method for producing three-dimensional parts from metal sheets. Although single-point incremental forming is a suitable method for rapid pro...

Achieving maximum dimensional accuracy and surface quality at the shortest possible time in single-point incremental forming via multi-objective optimization:

Lightweight materials, such as titanium alloys, magnesium alloys, and aluminium alloys, are characterised by unusual combinations of high strength, corrosion resistance, and low weight. However, some of the grades of these alloys exhibit poor formability at room temperature, which limits their application in sheet metal-forming processes. Lightweight materials are used extensively in the automobile and aerospace industries, leading to increasing demands for advanced forming technologies. This article presents a brief overview of state-of-the-art methods of incremental sheet forming (ISF) for lightweight materials with a special emphasis on the research published in 2015–2021. First, a review of the incremental forming method is provided. Next, the effect of the process conditions (i.e., forming tool, forming path, forming parameters) on the surface finish of drawpieces, geometric accuracy, and process formability of the sheet metals in conventional ISF and thermally-assisted ISF variants are considered. Special attention is given to a review of the effects of contact conditions between the tool and sheet metal on material deformation. The previous publications related to emerging incremental forming technologies, i.e., laser-assisted ISF, water jet ISF, electrically-assisted ISF and ultrasonic-assisted ISF, are also reviewed. The paper seeks to guide and inspire researchers by identifying the current development trends of the valuable contributions made in the field of SPIF of lightweight metallic materials.

Emerging Trends in Single Point Incremental Sheet Forming of Lightweight Metals

Studying on properties of bio-oil by adding blended additive during aging

Single-point incremental forming is an innovative flexible and inexpensive technique to form sheet products when prototypes or small batches are required. The process allows complex geometries to be produced using a computer numerical control machine, eliminating the need for a special die. This study reports on the effects of four important single-point incremental forming process parameters on produced surface profile accuracies. The profile accuracy was estimated by measuring the side angle errors and surface roughness and also waviness and circularity of the product inner surface. Full factorial design of experiments was used to plan the study, and the analysis of variance was used to analyze and interpret the results. The results indicate that the tool diameter (d), step depth (s), and sheet thickness (t) have significant effects on the produced profile accuracy, while the feed rate (f) is not significant. As a general rule, thin sheets with greater tool diameters yielded the best surface quality. The results also show that controlling all surface quality features is complex because of the contradicting effects of, and interactions between, a number of the process parameters.

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Study of the Effect of Process Parameters on Surface Profile Accuracy in Single-Point Incremental Sheet Forming of AA1050-H14 Aluminum Alloy

In this work, copper ferrite (CuFe2O4) nanoparticles (NPs) were prepared by sol-gel auto-combustion method and were used for the degradation of tartrazine in aqueous solution by heterogeneous Fenton-like process. The NPs were characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), energy dispersive X-ray (EDX) and point of zero charge measurement (pHPZC). XRD confirmed the tetragonal spinel structure of CuFe2O4. The average particle size evaluated by Debye Scherrer equation was found to be 37.34 nm. FTIR spectrum shows two primary absorption bands characteristic of the spinel ferrites. The point of zero charge of the CuFe2O4 catalyst was about 6.9. Response surface methodology (RSM) was employed for the optimization of the degradation efficiency of tartrazine. Four important process parameters including catalyst loading (0.1–0.5 g/L), tartrazine concentration (30–50 mg/L), H2O2 concentration (35.28–70.56 mM) and temperature (30–50 °C) were optimized using the statistical Box-Behnken design. A quadratic model was developed and validated by the analysis of variances. Numerical optimization by desirability function was applied to identify the optimum conditions for maximum degradation efficiency of tartrazine. The optimum conditions were determined as 0.32 g/L of catalyst loading, 64.35 mM of H2O2, 30.63 mg/L of tartrazine concentration and 49.92 °C of temperature. The degradation efficiency of the catalyst remains stable after five times recovery and reuse. 

Heterogeneous Fenton-like degradation of tartrazine using CuFe2O4 nanoparticles synthesized by sol-gel combustion

Parameter Optimization for Surface Roughness and Wall Thickness on AA5052 Aluminium alloy by Incremental Forming using Response Surface Methodology

Comparison of FLD and Thickness Distribution on AA5052 Aluminium alloy Formed parts by Incremental Forming Process

Machining characteristics of silane-treated wheat husk biosilica in deionized water dielectric on EDM drilling of Ti-6Al-4 V alloy

Studies on application of image processing in various fields: An overview

In this study, a surface based strain measurement was used to determine the formability of the sheet metal. A strain measurement may employ manual calculation of plastic strains based on the reference circle and the deformed circle. The manual calculation method has a greater margin of error in the practical applications. In this paper, an attempt has been made to compare the formability by implementing three different theoretical approaches: Namely conventional method, least square method and digital based strain measurements. As the sheet metal was formed by a single point incremental process the etched circles get deformed into elliptical shapes approximately, image acquisition has been done before and after forming. The plastic strains of the deformed circle grids are calculated based on the nondeformed reference. The coordinates of the deformed circles are measured by various image processing steps. Finally the strains obtained from the deformed circle are used to plot the forming limit diagram. To evaluate the accuracy of the system, the conventional, least square and digital based method of prediction of the forming limit diagram was compared. Conventional method and least square method have marginal error when compared with digital based processing method. Measurement of strain based on image processing agrees well and can be used to improve the accuracy and to reduce the measurement error in prediction of forming limit diagram.

V. Mugendiran

Papers

Parameter Optimization for Surface Roughness and Wall Thickness on AA5052 Aluminium alloy by Incremental Forming using Response Surface Methodology

Comparison of FLD and Thickness Distribution on AA5052 Aluminium alloy Formed parts by Incremental Forming Process

Machining characteristics of silane-treated wheat husk biosilica in deionized water dielectric on EDM drilling of Ti-6Al-4 V alloy

Studies on application of image processing in various fields: An overview

Comparison of plastic strains on AA5052 by single point incremental forming process using digital image processing