Quality evaluation of aluminum-AA6061 truncated cone deformed by single point incremental forming

The manufacturing industry nowadays is focused on newer modern manufacturing methods such as single point incremental forming (SPIF). The SPIF process is getting more popular due to its ability for rapid prototyping and forming complex geometry with simple steps. It can also be used for manufacturin...

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Bibliographic Details
Published in:Journal of the Brazilian Society of Mechanical Sciences and Engineering 2022-09, Vol.44 (9), Article 420
Main Authors: Akhavan Farid, Ali, Shen, Foong Shin, Rahimian Koloor, Seyed Saeid, Petrů, Michal
Format: Article
Language:English
Subjects:
Aluminum
Aluminum base alloys
Deformation
Engineering
Feed rate
Forming techniques
Manufacturing
Mechanical Engineering
Metal sheets
Parameters
Production methods
Quality assessment
Rapid prototyping
Sheet material
Surface hardness
Surface properties
Technical Paper
Workpieces
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Summary:The manufacturing industry nowadays is focused on newer modern manufacturing methods such as single point incremental forming (SPIF). The SPIF process is getting more popular due to its ability for rapid prototyping and forming complex geometry with simple steps. It can also be used for manufacturing custom-made products to meet unique customer requirements. Few forming parameters will affect the quality of the final workpiece such as the angle of forming, spindle speed, feed rate, tool path, sheet material, step size, tool size, and lubricant. The purpose of this research is to investigate the effect of forming parameters such as feed rate and step size on the quality aspects of the deformed aluminum sheet by SPIF. Therefore, forming was carried out by a CNC machine on a 1.6 mm-thick aluminum AA 6061 metal sheet with three different feed rates of 500, 1000, and 1500 mm/min and three different step sizes of 0.2, 0.6, and 1 mm. The findings revealed that feed rate and step size are two extremely important factors that have a considerable impact on forming outputs, with some interaction effects. It was also observed that rupture of metal sheet is likely during forming if the combination of high step size and low feed rate is employed. The feed rate is beneficial in achieving a better surface quality, while the step size is important in controlling dimension accuracy and final surface hardness.
ISSN:1678-5878
1806-3691
DOI:10.1007/s40430-022-03730-5