Effect of Process Parameters on Forming Forces in Single Point Incremental Forming (SPIF) Process

Abstract

Single Point Incremental Sheet Forming (SPIF) process is an advanced flexible manufacturing process in the sheet metal forming industry. This process is gaining importance because higher formability can be achieved compared to conventional stamping process. In the present work, AA1100-F and AA1050-O grade aluminum sheet, which are widely used in sheet metal industry, have been selected for experimental work. It is also aimed to measure the forces involved in SPIF. A set-up using a load cell has been developed for force measurement. Moreover the studies of the process variables have been done using the full factorial method. Groove test has been performed as a preliminary experiment to understand the effect of the process parameters on the formability and forces involved. Final Experiments are done by forming a variable angle cone (cone with circular generatrix). Explicit analysis of the forming process is carried out using LS-DYNA software. Results of experimental work and FE Analysis are in good agreement. Statistical analysis is done using Minitab software. A variable angle cone shape with depth 45mm could be formed with strain at fracture about 300%.