Optimization of Surface Roughness and Improving Profile Accuracy in SPIF (Single Point Incremental Forming) Process
01 Jan 2015-
TL;DR: In this article, the effect of three various parameters (step depth, tool diameter, and feed rate) on the surface roughness and profile accuracy were measured over four points in conical profile.
Abstract: Single point incremental forming (SPIF) process is novel sheet metal process. In this process, a sheet blank is tightly held at the periphery and a single-point tool deforms it in incremental fashion during successive downward steps the tool moves according to a pre-defined trajectory. As a result three dimensional shaping can be obtained without die. As a critical product quality constraint, surface roughness and profile accuracy is the weak point is the incremental sheet metal forming. It is very important to identify the impact of the forming parameter on the surface roughness and the surface finish at the production stage. This paper presents a systematic approach to modeling and optimizing the effect of three various parameter’s (step depth, tool diameter, and feed rate) on the surface roughness and the profile accuracy were measure over four points in conical profile. The experiments are conducted on AA 1200 H14 aluminum alloy and analyzed by the Response surface methodology wit box-behnken design. The optimum conditions for minimizing of overall roughness are determine as step dept 0.2mm, tool diameter 12mm, feed rate 1000mm/min. and for profile accuracy the percentage error is 4%.
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TL;DR: In this article, the feasibility of socket fittings, applied to the femoral amputees, aimed at slowing wear between friction surfaces, has been analyzed as a formability indicator; also, the surface roughness has been addressed.
Abstract: Incremental sheet forming (ISF) is a relatively recent technology that allows producing highly custom-made components at a reasonable manufacturing cost. Single-point incremental sheet forming (SPIF) is one of the easiest ISF processes. In this sense, recent published results have revealed an increasing interest in shaping components for biomedical uses. This paper focuses on the establishment of a platform dedicated to produce biomedical complex geometry component. The main issue to be carried out is to improve the quality and the precision of manufactured products. The study shows the feasibility of socket fittings, applied to the femoral amputees, aimed at slowing wear between friction surfaces. The thinning has been analyzed as a formability indicator; also, the surface roughness has been addressed. The experimental results show a significant effect of the spindle speed in the ISF process of the increment on the surface roughness swept by the tool/sheet contact and the forming force. The analysis carried out on the deformed sheet shows a slight offset between the programmed surface, representing the real model, and the deformed surface obtained at the end of the process.
16 citations
TL;DR: In this article, the effects of the generatrix profile for two shapes of a truncated cone on forming forces, thickness distribution, shape accuracy, and surface roughness of the formed shape were investigated.
Abstract: The single-point incremental forming is one of two modes of the incremental sheet forming process. It is the most used in the manufacture of parts for small series and prototypes in various sectors such as aeronautics, biomedical field, and art pieces. In this work, two geometries of parts are investigated at the same process parameters (rotation speed, feed rate, step increment, sheet thickness, and tool diameter). The experimental tests are made with a CNC spinner milling machine. The blank sheet of mild steel is formed by means of a hemispherical tool with a 10-mm diameter. The forming tool follows the desired spiral path that is determined by a CAD model. The main objective of this paper is to study the effects of the generatrix profile for two shapes of a truncated cone (straight and circular generatrix) on forming forces, thickness distribution, shape accuracy, and surface roughness of the formed shape. Besides, a coefficient of shape is introduced from experimental and analytical vertical forces. The experimental results show that a better roughness surface quality is obtained in forming a straight generatrix and that a more uniform thickness distribution of the blank is obtained after thinning and shaping a circular generatrix. In order to examine the geometric accuracy of the parts, a Next Engine 3D scanner is used to rebuild the developed surfaces again and to make a comparison between the programmed and scanned profiles.
15 citations
References
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TL;DR: In this paper, the deformation mechanism of incremental sheet forming (ISF) is examined experimentally through forming specially prepared copper sheets, and the authors measured the strain distributions through the thickness of the sheets are measured for two configurations of ISF: two-point incremental forming (TPIF) and single point incremental forming(SPIF).
330 citations
TL;DR: In this paper, the effect of various combinations of tools and lubricants on the quality of the formed surface was studied by measuring the surface roughness with a surface rouness meter and examining the surface with a scanning electron microscope (SEM).
102 citations
TL;DR: In this article, the impact of four parameters (step down, feed rate, sheet thickness, and tool diameter) on surface roughness is analyzed using the response surface methodology with Box-Behnken design.
Abstract: As a critical product quality constraint, surface roughness is regarded as a weak point in incremental sheet forming (ISF). It is of great importance to identify the impact of forming parameters on the surface roughness and optimize the surface finish at the production stage. This paper proposes a systematic approach to modeling and optimizing surface roughness in ISF. The quantitative effects of four parameters (step down, feed rate, sheet thickness, and tool diameter) on surface roughness are analyzed using the response surface methodology with Box–Behnken design. The multi-objective function is used to evaluate the overall surface roughness in terms of the tool-sheet contact surface roughness, i.e., internal surface roughness and the noncontact surface roughness, i.e., external surface roughness. Additionally, the average surface roughness (R a) on each surface is measured along the tool-path step-down direction taking the impact of sheet roll marks into account. The optimal conditions for the minimiza...
72 citations
TL;DR: In this paper, the authors proposed an energy analysis of single point incremental forming processes (SPIF) and compared the electrical energy consumption of two different setups, namely a CNC milling machine and an innovative high speed incremental forming process performed on CNC-turning machine.
23 citations
01 Jan 2010
TL;DR: A study based on the experimental research referred to in the single point incremental forming (SPIF) process was used to establish the influence of geometrical parameters on the forces developed in the process.
Abstract: This paper presents a study regarding the influence of the geometrical parameters of the incremental forming process on the forces developed in the process, on the precision and the surface quality of the parts obtained through it A study based on the experimental research referred to in the single point incremental forming (SPIF) process was used to establish the influence of geometrical parameters on the forces developed in the process With regard to precision, errors appearing in the case of parts realised through incremental forming were measured and recorded by means of a coordinates measuring machine With regard to the surface quality, the roughness of the surfaces that come into direct contact with the punch was determined
12 citations