Surface Roughness in Incremental Sheet Metal Forming of AA5052

Abstract:

This paper presents the effect of forming parameters on the arithmetic mean surface roughness (Ra) of aluminum alloy built by a single-point incremental sheet metal forming process. Three investigated parameters are feed rate (12.5, 25 and 50 in/min), depth increment (0.015 and 0.030 in), and wall angle (45° and 60°). The results show that wall angle, depth increment and its interaction play an important role on the surface roughness, while feed rate has little effect. The optimal forming conditions for minimum surface roughness are feed rate of 25 in/min, depth increment of 0.015 in and wall angle of 45°.

• Periodical: Advanced Materials Research (Volumes 753-755)
• Pages: 203-206
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.753-755.203
• Online since: August 2013
• Authors: On-Uma Lasunon
• Keywords: Aluminium Alloy, Single-Point Incremental Sheet Metal Forming, Surface Roughness (SR)

References

[1] E. Hagan and J. Jeswiet, A review of conventional and modern single-point sheet metal forming methods, Proc. IMechE Part B: J. Engineering Manufacture. 217 (2003), p.213.

DOI: 10.1243/095440503321148858

[2] S. Matsubara, Incremental Backward Bulge Forming of a Sheet Metal with a Hemispherical Tool, J. JSTP. 35 (1994), p.1311.

[3] H. Iseki and T. Naganawa, Vertical wall surface forming of rectangular shell using multistage incremental forming with spherical and cylindrical rollers, J. Mater. Process. Techno. 130-131 (2002), p.675.

DOI: 10.1016/s0924-0136(02)00735-5

[4] S.J. Yoon and D.Y. Yang, Investigation into a new incremental forming process using an adjustable punch set for the manufacture of a doubly curved sheet metal, Proc. IMechE. Part B: J. Engineering Manufacture 215 (2001), p.991.

DOI: 10.1243/0954405011518791

[5] M.P. Groover: Fundamentals of Modern Manufacturing, Prentice-Hall International, Inc., New Jersey (1996).

[6] E. Hagan and J. Jeswiet, Analysis of surface roughness for parts formed by computer numerical controlled incremental forming, Proc. IMechE Part B: J. Engineering Manufacture. 218 (2004), p.1307.

DOI: 10.1243/0954405042323559

[7] K. Allan and S. Hamilton: Friction and external surface roughness in single point incremental forming, Thesis, Queen's University, Canada (2010).

[8] A. Bhattacharya, K. Maneesh, N.V. Reddy and J. Cao, Formability and surface finish studies in single point incremental forming, J. Manuf Sci Eng 133 (2011), p.621.

DOI: 10.1115/1.4005458

[9] D.C. Montgomery: Design and Analysis of Experiments, fifth ed., John Wiley & Sons, Inc., New York (2001).

[10] Minitab, Inc.: MINITAB Release 14 (Stat Guide) (2000-2003).