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Performance evaluation of high-speed incremental sheet forming technology for AA5754 H22 aluminum and DC04 steel sheets

Wybrane pełne teksty z tego czasopisma
Identyfikatory
Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
Incremental sheet forming (ISF) has received tremendous attraction in industrial, academia and research segments due to its inherent advantages. To deploy ISF technology in the manufacturing sector, various aspects have to be addressed such as geometrical accuracy, non-homogenous thickness distribution, and process slowness. In this study, extensive experimental work was performed to satisfy the industrial requirements. The influence of forming parameters (step depth, forming wall angle and feed rate) was investigated to access the ISF feasibility at higher speeds when forming the AA5754-H22 aluminum alloy and DC04 steel. The surface roughness, thickness distribution, and microhardness tests were carried out for the samples, which were successfully formed at the higher levels of process parameters. These experimental results were obtained at different locations on the sheet after forming. The analysis has revealed that the possible reduction in the execution time is up to 84% faster for AA5754 H22 aluminum alloy and 74% in case of DC04 steel. In this way, the current study not only provides the necessary framework for the future development of ISF but also commercialization of this technology.
Słowa kluczowe
Rocznik
Strony
1275--1287
Opis fizyczny
Bibliogr. 34 poz., rys., tab., wykr.
Twórcy
autor
  • Mechanical Engineering Department, National Institute of Technology, Warangal 506004, India
  • Faculty of Production Engineering, Warsaw University of Technology, Narbutta 85, Warsaw, Poland
autor
  • Mechanical Engineering Department, National Institute of Technology, Warangal 506004, India
autor
  • Mechanical Engineering Department, National Institute of Technology, Warangal 506004, India
autor
  • Faculty of Production Engineering, Warsaw University of Technology, Narbutta 85, Warsaw, Poland
autor
  • Faculty of Production Engineering, Warsaw University of Technology, Narbutta 85, Warsaw, Poland
Bibliografia
  • [1] I. Cerro, E. Maidagan, J. Arana, A. Rivero, P.P. Rodríguez, Theoretical and experimental analysis of the dieless incremental sheet forming process, J. Mater. Process. Technol. 177 (1–3) (2006) 404–408.
  • [2] G. Ambrogio, L. Filice, F.A. Micari, force measuring based strategy for failure prevention in incremental forming, J. Mater. Process. Technol. 177 (1–3) (2006) 413–416.
  • [3] C. Raju, C.S. Narayanan, FLD and Fractography Analysis of Multiple Sheet Single Point Incremental Forming, Transection of Indian Institute of Metals, 2015, http://dx.doi.org/10.1007/s12666-015-0679-5.
  • [4] M. Durante, A. Formisano, A. Langella, F.M.C. Minutolo, The influence of tool rotation on an incremental forming process, J. Mater. Process. Technol. 209 (9) (2009) 4621–4626.
  • [5] G. Ambrogio, L. Filice, F. Gagliardi, F. Micari, Sheet thinning prediction in single point incremental forming, Adv. Mater. Res. 6–8 (2005) 479–486.
  • [6] N.G. Azevedo, J.S. Farias, R.P. Bastos, P. Teixeira, J.P. Davim, R. J. Alves de Sousa, Lubrication aspects during Single Point Incremental Forming for steel and aluminum materials, Int. J. Prec. Eng. Manuf. 16 (3) (2015) 589–595.
  • [7] A. Bhattacharya, K. Maneesh, N.V. Reddy, J. Cao, Formability and surface finish studies in single point incremental forming, J. Manuf. Sci. Eng. 133 (6) (2011).
  • [8] M.J. Mirnia, B.M. Dariani, H. Vanhove, J.R. Duflou, Thickness improvement in single point incremental forming deduced by sequential limit analysis, Int. J. Adv. Manuf. Technol. 70 (9–12) (2014) 2029–2041.
  • [9] V. Gulati, A. Aryal, P. Katyal, A. Goswami, Process parameters optimization in single point incremental forming, J. Inst. Eng. (India) Ser. C 97 (2) (2015) 221–229.
  • [10] S. Echrif, M. Hrairi, Significant parameters for the surface roughness in incremental forming process, Mater. Manuf. Process. 29 (2014) 697–703.
  • [11] G. Ambrogio, F. Gagliardi, S. Bruschi, L. Filice, On the highspeed single point incremental forming of titanium alloys, CIRP Ann. Manuf. Technol. 62 (1) (2013) 243–246.
  • [12] Y. Li, Z. Liu, W.J.T. Daniel, P.A. Meehan, Simulation and experimental observations of effect of different contact interfaces on the incremental sheet forming process materials and manufacturing processes 29 (2014)121–128.
  • [13] V.A.M. Cristino, M.B. Silva, P.A.F. Martins, Hole-flanging of metals and polymers produced by single point incremental forming, Int. J. Mater. Prod. Technol. 50 (1) (2015) 37–48.
  • [14] G. Fan, L. Gao, Numerical simulation and experimental investigation to improve the dimensional accuracy In electric hot incremental forming of Ti–6Al–4V titanium sheet, Int. J. Adv. Manuf. Technol. 72 (5–8) (2014) 1133–1141.
  • [15] S. Golabi, H. Khazaali, Determining frustum depth of 304 stainless steel plates with various diameters and thicknesses by incremental forming, J. Mech. Sci. Technol. 28 (8) (2014) 3273–3278.
  • [16] K.A. Ghamdi, G. Hussain, S.I. Butt, Force variations with defects and a force-based strategy to control defects in SPIF, Mater. Manuf. Process. 29 (2014) 1197–1204.
  • [17] M. Azaouzi, N. Lebaal, Tool path optimization for single point incremental sheet forming using response surface method, Simul. Model. Pract. Theory 24 (2012) 49–58.
  • [18] G. Hussain, H.R. Khan, L. Gao, N. Hayat, Guidelines for toolsize selection for single-point incremental forming of an aerospace alloy, Mater. Manuf. Process. 28 (3) (2013) 324–329.
  • [19] J. Li, C. Li, T. Zhou, Thickness distribution and mechanical property of sheet metal incremental forming based on numerical simulation, Trans. Nonferrous Met. Soc. China 22 (2012) s54–s60.
  • [20] H. Khalatbari, A. Iqbal, X. Shi, L. Gao, G. Hussain, M. Hashemipour, High-speed incremental forming process: a trade-off between formability and time efficiency, Mater. Manuf. Process. 30 (2015) 1354–1363.
  • [21] M. Ham, J. Jeswiet, Single point incremental forming limits using a boxbehnken design of experiment, Key Eng. Mater. 344 (2007) 629–636.
  • [22] J.J. Park, Y.H. Kim, Fundamental studies on the incremental sheet metal forming technique, J. Mater. Process. Technol. 140 (1–3) (2003) 447–453.
  • [23] Z. Liu, Y. Li, P.A. Meehan, Experimental investigation of mechanical properties, formability and force measurement for AA7075-O aluminum alloy sheets formed by incremental forming, Int. J. Prec. Eng. Manuf. 14 (11) (2013) 1891–1899.
  • [24] A. Kocanda, C. Jasinski, Extended evaluation of Erichsen cupping test results by means of laser speckle, Arch. Civ. Mech. Eng. 14 (2015) 211–216.
  • [25] V.A. Cristino, L. Montanari, M.B. Silva, A.G. Atkins, P.A.F. Martins, Fracture in hole-flanging produced by single point incremental forming, Int. J. Mech. Sci. 83 (2014) 146–154.
  • [26] A. Mulay, S. Ben, S. Ismail, A. Kocanda, Experimental investigations into the effects of SPIF forming conditions on surface roughness and formability by design of experiments, J. Braz. Soc. Mech. Sci. Eng. (2017), http://dx.doi.org/10.1007/s40430-016-0703-7.
  • [27] G. Centeno, I. Bagudanch, A.J. Martínez-Donaire, M.L. García-Romeu, C. Vallellano, Critical analysis of necking and fracture limit strains and forming forces in single-point incremental forming, Mater. Des. 63 (2014) 20–29.
  • [28] G. Hussain, L. Gao, Z.Y. Zhang, Formability evaluation of a pure titanium sheet in the cold incremental forming process, Int. J. Adv. Manuf. Technol. 37 (9–10) (2008) 920–926.
  • [29] K. Dai, Z.R. Wang, Y. Fang, CNC incremental sheet forming of an axially symmetric specimen and the locus of optimization, J. Mater. Process. Technol. 102 (1) (2000) 164–167.
  • [30] S. Kurra, S.D. Bagade, S.P. Regalla, Deformation behavior of extra deep drawing steel in single-point incremental.
  • [31] M. Otsu, M. Yasunaga, M. Matsuda, K. Takashima, Friction stir incremental forming of A2017 aluminum sheets, Proc. Eng. 81 (2014) 2318–2323.
  • [32] Z. Liu, S. Liu, Y. Li, P. Meehan, Modelling and optimization of surface roughness in incremental sheet forming using a multiobjective function, Mater. Manuf. Process. 29 (2014) 808–818.
  • [33] J. Jeswiet, F. Micari, G. Hirt, A. Bramley, J. Duflou, J. Allwood, Asymmetric single point incremental forming of sheet metal, CIRP Ann. Manuf. Technol. 54 (2) (2005) 623–649.
  • [34] S.P. Shanmuganatan, V.S.S. Kumar, Modeling of incremental forming process parameters of Al 3003 (O) by response surface methodology, Proc. Eng. 97 (2014) 346–356.
Uwagi
PL
Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2019)
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-d0b3d572-93f7-4e66-9c09-13daa09af6a3
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