Performance evaluation of high-speed incremental sheet forming technology for AA5754 H22 aluminum and DC04 steel sheets

• Published in: Archives of Civil and Mechanical Engineering 2018-09, Vol.18 (4), p.1275-1287
• Main Authors: Mulay, Amrut, Ben, B. Satish, Ismail, Syed, Kocanda, Andrzej, Jasiński, Cezary
• Format: Article
• Language: English
• Subjects: Aluminum alloys; Aluminum base alloys; Civil Engineering; Commercialization; Engineering; Feed rate; Forming; Forming techniques; Fracture; Geometric accuracy; Incremental; Low carbon steels; Mechanical Engineering; Metal sheets; Microhardness; Original Research Article; Performance evaluation; Process parameters; Roughness; Structural Materials; Surface roughness; Thickness
• ISSN: 1644-9665; 2083-3318
• DOI: 10.1016/j.acme.2018.03.004

Incremental sheet forming (ISF) has received tremendous attraction in industrial, academia and research segments due to its inherent advantages. To deploy ISF technology in the manufacturing sector, various aspects have to be addressed such as geometrical accuracy, non-homogenous thickness distribution, and process slowness. In this study, extensive experimental work was performed to satisfy the industrial requirements. The influence of forming parameters (step depth, forming wall angle and feed rate) was investigated to access the ISF feasibility at higher speeds when forming the AA5754-H22 aluminum alloy and DC04 steel. The surface roughness, thickness distribution, and microhardness tests were carried out for the samples, which were successfully formed at the higher levels of process parameters. These experimental results were obtained at different locations on the sheet after forming. The analysis has revealed that the possible reduction in the execution time is up to 84% faster for AA5754 H22 aluminum alloy and 74% in case of DC04 steel. In this way, the current study not only provides the necessary framework for the future development of ISF but also commercialization of this technology.