Effect of Process Parameters on Formability of aa1100-f Aluminum Alloy In Single Point Incremental Forming

Abstract

Single point incremental forming is a modern, dieless sheet metal forming technique applied for the small batch production and custom made products of the various shape and dimensions. This process is carried out at room temperature (cold forming) and requires a VMC machine, a spherical ended tool and fixture to clamp the sheet being formed. In this work experimental investigation of AA1100-F grade Aluminium sheet is carried out by performing a cone test on Vertical Machining Centre. Tool and fixture have been developed for single point incremental forming process. Factors affecting the process are identified and experiments are carried out using Design Of Experiments technique. Effect of the factors on response variables (fractured depth, forming time, surface roughness, forming force and thickness strain) is studied. Minitab software is used for the statistical analysis of the data. Explicit finite element analysis is carried out using LS-DYNA software. Experiments have also been performed on AA1050-O aluminium sheet for comparison purpose.