Study of the effect of process factors on the wear rate and surface integrity in incremental point forming of AA6061 aluminum alloy

• Autorzy: Mughir Walaa Amer , Jasim Hussein Hatem

Identyfikatory

DOI

10.12913/22998624/197369

• Języki publikacji: EN

Abstrakty

EN

Incremental point forming is a contemporary method employed in sheet metal forming to achieve great flexibility in fabrication of intricate forms, eliminating the requirement for specific mold. According to its exceptional mechanical characteristics and low weight, this method is particularly employed in the production of aluminium alloys. The essential aim of this research is to examine the deformation mechanisms and discuss the mechanical properties of aluminium during the incremental forming process. The aim was to examine how various process parameters influence the surface properties, hardness, and wear resistance of the workpieces using aluminium alloy type AA6061. The parameters under investigation are increment step down size, feed rate, and spindle rotational speed. Furthermore, the impact of these factors on the forming process was investigated using several methodologies, including the Taguchi method for parameter optimization and surface analysis. The findings of this study demonstrate that spindle rotation speed exerted a substantial influence on both surface roughness and hardness, accounting for 63.41% for hardness and 52.19% for roughness. In terms of wear rate, the step size had the most significant impact, accounting for 48.53%.

Słowa kluczowe

EN

wear resistance; microhardness; surface roughness; ANOVA; Taguchi design; AA6061; aluminum alloy; analysis of variance

• Wydawca: Lublin University of Technology ; Polish Society of Ecological Engineering (PTIE), Branch of PTIE in Lublin
• Czasopismo: Advances in Science and Technology. Research Journal
• Rocznik: 2025
• Tom: Vol. 19, no. 3
• Strony: 84--95
• Opis fizyczny: Bibliogr. 21 poz., fig., tab.

Twórcy

autor

Mughir Walaa Amer

• Material Engineering, Department of Metallurgical, University of Babylon, 51001, Babil, Iraq

• https://orcid.org/0000-0002-0017-6618

autor

Jasim Hussein Hatem

• Technical institute in Babylon, Al-Furat Al-Awsat Technical University, 51001, Babil, Iraq

Bibliografia

• 1. Szpunar M, Ostrowski R, Trzepieciński T, Kaščák L. Central composite design optimisation in single point incremental forming of truncated cones from commercially pure titanium grade 2 sheet metals. Materials. 2021 Jul 1; 14(13).
• 2. Gohil A, Modi B. Review of the effect of process parameters on performance measures in the incremental sheet forming process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. SAGE Publications Ltd; 2021; 235, 303–32.
• 3. Cooper DR, Gutowski TG. Prospective environmental analyses of emerging technology: A critique, a proposed methodology, and a case study on incremental sheet forming. Journal of Industrial Ecology. 2020 Feb 1; 24(1): 38–51.
• 4. Barnwal VK, Chakrabarty S, Tewari A, Narasimhan K, Mishra SK. Forming behavior and microstructural evolution during single point incremental forming process of AA-6061 aluminum alloy sheet. International Journal of Advanced Manufacturing Technology. 2018 Mar 1; 95(1–4): 921–35.
• 5. Basak S, Prasad KS, Mehto A, Bagchi J, Ganesh YS, Mohanty S, et al. Parameter optimization and texture evolution in single point incremental sheet forming process. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2020 Jan 1; 234(1–2): 126–39.
• 6. Hussain G, Ilyas M, Lemopi Isidore Bb, Khan Wa. Mechanical properties and microstructure evolution in incremental forming of AA5754 and AA6061 aluminum alloys. Transactions of Nonferrous Metals Society of China (English Edition). 2020 Jan 1; 30(1): 51–64.
• 7. Chang Z, Yang M, Chen J. Experimental investigations on deformation characteristics in microstructure level during incremental forming of AA5052 sheet. Journal of Materials Processing Technology. 2021 May 1; 291.
• 8. Mishra S, Yazar KU, Kar A, Lingam R, Reddy Nv, Prakash O, et al. Texture and microstructure evolution during single-point incremental forming of commercially pure titanium. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science. 2021 Jan 1; 52(1): 151–66.
• 9. Yoganjaneyulu G, Vigneshwaran S, Palanivel R, Alblawi A, Rasheed MA, Laubscher RF. Effect of Tool rotational speed on the microstructure and associated mechanical properties of incrementally formed commercially pure titanium. Journal of Materials Engineering and Performance. 2021 Oct 1; 30(10): 7636–44.
• 10. Shrivastava P, Tandon P. Microstructure and texture based analysis of forming behavior and deformation mechanism of AA1050 sheet during Single Point Incremental Forming. Journal of Materials Processing Technology. 2019 Apr 1; 266: 292–310.
• 11. Murugesan M, Yu JH, Jung KS, Cho SM, Bhandari KS, Lee CW. Optimization of forming parameters in incremental sheet forming of AA3003-H18 sheets using Taguchi method. Materials. 2022 Feb 1; 15(4).
• 12. Najm SM, Paniti I, Trzepieciński T, Nama SA, Viharos ZJ, Jacso A. Parametric effects of single point incremental forming on hardness of AA1100 aluminium alloy sheets. Materials. 2021 Dec 1; 14(23).
• 13. Dabwan A, Ragab AE, Saleh MA, Anwar S, Ghaleb AM, Rehman AU. Study of the effect of process parameters on surface profile accuracy in single-point incremental sheet forming of AA1050-H14 aluminum alloy. Advances in Materials Science and Engineering, 2020.
• 14. Kumar V, Kumar R. Investigation of surface roughness in incremental sheet forming of AA 2014-T6 using Taguchi’s method. In: Journal of Physics: Conference Series. Institute of Physics Publishing; 2020.
• 15. Trzepieciński T, Kubit A, Dzierwa A, Krasowski B, Jurczak W. Surface finish analysis in single point incremental sheet forming of rib-stiffened 2024-T3 and 7075-T6 alclad aluminium alloy panels. Materials. 2021 Mar 27; 14(7).
• 16. Coman CC, Mazurchevici SN, Carausu C, Nedelcu D. Analysis of incremental sheet forming of aluminum alloy. Materials. 2023 Oct 1; 16(19).
• 17. Habeeb HA, Jweeg MJ, Khleif AA. Effect of the single-point incremental forming process parameters on the surface roughness of aluminum alloy Al 2024-O draw pieces. Advances in Science and Technology Research Journal. 2023; 17(6): 155–63.
• 18. Tayebi P, Hashemi R. Study of single point incremental forming limits of Al 1050/Mg-AZ31B two-layer sheets fabricated by roll bonding technique: Finite element simulation and experiment. Journal of Materials Research and Technology. 2024 Mar 1; 29: 149–69.
• 19. Mughir WA, Jaleel AK. Effect of process parameters on the geometric accuracy of AA1050 alloy during the incremental forming process. Journal of Mechanical Engineering Research and Developments. 2019; 42(5): 168–71.
• 20. Ilyas, M, Hussain, G, Rashid, H, & Alkahtani, M. Influence of forming parameters on the mechanical behavior of a thin aluminum sheet processed through single point incremental forming. Metals, 2020; 10(11), 1461.
• 21. Vander Voort, G. F., Lampman, S. R., Sanders, B. R., Anton, G. J., Polakowski, C., Kinson, J.,... & Scott Jr, W. W. ASM handbook. Metallography and microstructures, 2004; 9, 44073–000.

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr POPUL/SP/0154/2024/02 w ramach programu "Społeczna odpowiedzialność nauki II" - moduł: Popularyzacja nauki (2025).