: Studies On Ultrasonic Assisted Single Point Incremental Forming

Abstract

Incremental sheet forming is one of the latest process in sheet metal forming industry which has drawn attention of various researchers. Process has shown improved formability compared to stamping process. Single Point Incremental forming process requires only hemispherical tool. As no die is required, the process is also termed as “die-less forming” process. In this work experimental investigation of Aluminium sheet is carried out by performing a groove test and pyramid test on Vertical Machining Center. Factors affecting the process are identified and experiments are carried out using fractional factorial method (groove test) and full factorial method (pyramid test). Effect of the factors on fractured depth, forming time, surface finish, strain distribution and thickness distribution is studied. For the pyramid test maximum wall angle achieved is also studied. Minitab 17 software is used for the statistical analysis of the data. Simulation of groove test and pyramid test is carried out using LS DYNA. The CNC program for Groove and pyramid test is programmed in C++ language. Another C++ program is prepared to obtain time-position data for LS DYNA analysis. The use of ultrasonic vibration in single point incremental forming is studied performing a groove test. Effect of step depth is studied on fracture depth, surface roughness and strain distribution.