Sensitivity analysis and optimization of the surface roughness in the incremental forming of mild steel sheets

Document Type : Article

Authors

1 Department of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran.

2 Automotive Simulation and Optimal Design Research Laboratory, School of Automotive Engineering, Iran University of Science and Technology, Tehran, Iran

Abstract

Flexibility and simple tooling make the incremental sheet forming (ISF) a great process to create complex shapes from mild steel sheets. It is a significant issue to reduce the surface roughness (SR) which is a weakness in the manufacturing the mild steel parts in ISF process.
The purpose of this study is to investigate the effects of the ISF process parameters on the SR of the mild steel sheets. Feed rate, tool diameter, vertical step and spindle speed are chosen as four input variables in the experimental tests. Taguchi design of experiment (DOE) and the analysis of variance (ANVOA) are used to optimize the SR by investigating the parameters effects and their interactions. According to the obtained results, the vertical step reduction and increase in tool diameter, decrease the roughness on the surface of the mild steel sheets during the single-point incremental forming (SPIF). In addition, the tool speed in term of both rotation and feed have little effect on the surface roughness. The results of a validation test demonstrates that the Taguchi technique and the ANOVA can effectively optimize the level of each variable to ensure the best SR.

Keywords

References

References:
1. Jeswiet, J. and Hagan, E. "Rapid proto-typing of a headlight with sheet metal", 9th International Conference on Sheet Metal Forming, Leuven, Belgium, pp. 165-170 (2001).
2. Leach, D., Green, A.J., and Bramley, A.N. "A new incremental sheet forming process for small batch and prototype parts", 9th International Conference on Sheet Metal Forming, Leuven, Belgium, pp. 211-218 (2001).
3. Filice, L., Fratini, L., and Micari, F. "Analysis of material formability in incremental forming", CIRP Annals- Manufacturing Technology, 51(1), pp. 199- 202 (2002).
4. Powell, N. and Andrew, C. "Incremental forming of anged sheet metal components without dedicated dies", Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 206(1), pp. 41-47 (1992).
5. Matsubara, S. "Incremental backward bulge forming of a sheet metal with a hemispherical tool", Journal of the Japan Society for Technology of Plasticity, 35(406), pp. 1311-1316 (1994).
6. Silva, M.B. and Martins, P.A. "Two-point incremental forming with partial die: theory and experimentation", Journal of Material Engineering Performance, 22(4), pp. 1018-1027 (2013).
7. Hagan, E. and Jeswiet, J. "Analysis of surface roughness for parts formed by computer numerical controlled incremental forming", Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 218(10), pp. 1307-1312 (2004).
8. Cerro, I., Maidagan, E., Arana, J., et al. "Theoretical and experimental analysis of the dieless incremental sheet forming process", Journal of Materials Processing Technology, 177(1-3), pp. 404-408 (2006).
9. Durante, M., Formisano, A., Langella, A., et al. "The influence of tool rotation on an incremental forming process", Journal of Materials Processing Technology, 209(9), pp. 4621-4626 (2009).
10. Hamilton, K. and Jeswiet, J. "Single point incremental forming at high feed rates and rotational speeds: Surface and structural consequences", CIRP Annals-Manufacturing Technology, 59(1), pp. 311-314 (2010).
11. Bhattacharya, A., Maneesh, K., Venkata Reddy, N., et al. "Formability and surface finish studies in single point incremental forming", Journal of Manufacturing Science and Engineering, 133(6), pp. 061020-1- 061020-8 (2011).
12. Lu, B., Fang, Y., Xu, D.K., et al. "Mechanism investigation of friction-related effects in single point incremental forming using a developed oblique rollerball tool", International Journal of Machine Tools & Manufacture, 85, pp. 14-29 (2014).
13. Echrif, S.B.M. and Hrairi, M. "Significant parameters for the surface roughness in incremental forming process", Materials and Manufacturing Processes, 29(6), pp. 697-703 (2014).
14. Gulati, V., Aryal, A., and Katyal, P. "Process parameters optimization in single point incremental forming", Journal of the Institution of Engineers (India): Series C, 97(2), pp. 185-193 (2016).
15. Yao, Z., Li, Y., Yang, M., et al. "Parameter optimization for deformation energy and forming quality in single point incremental forming process using response surface methodology", Journal of Advances in Mechanical Engineering, 9(7), pp. 1-15 (2017).
16. Taherkhani, A., Basti, A., and Nariman Zadeh, N. "Achieving maximum dimensional accuracy and surface quality at the shortest possible time in single-point incremental forming via multi-objective optimization", Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 233(3), pp. 900-913 (2018).
17. Asghari, A., Sarband, A., and Habibnia, M. "Optimization of multiple quality characteristics in twopoint incremental forming of aluminum 1050 by grey relational analysis", Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 203, pp. 1989-1996 (2017).
18. Khalkhali, A., Noraie, H., and Sarmadi, M. "Sensitivity analysis and optimization of hot-stamping process of automotive components using analysis of variance and Taguchi technique", Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 231(4), pp. 732-746 (2016).
19. Tang, L., Ma, Y., Wang, J., et al. "Robust parameter design of supply chain inventory policy considering the uncertainty of demand and lead time", Scientia Iranica, 26(5), pp. 1-34 (2018). DOI:10.24200/sci.2018.5205.1217.
20. Roy, R.K., A Primer on the Taguchi Method, Society of Manufacturing Engineers (SME), Michigan, USA (2010).
21. Malkin, S. and Guo, C., Grinding Technology-Theory and Applications of Machining with Abrasives, Industrial Press, New York, USA (2008).
22. Shojaeefard, M.H., Kalkhali, A., and Shahbaz, S.O. "Analysis and optimization of the surface waviness in the single-point incremental sheet metal forming", Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 233(4), pp. 919-925 (2018).
23. Moghaddam, M. and Kolahan, F. "Using combined artificial neural network and particle swarm optimization algorithm for modeling and optimization of electrical discharge machining process", Scientia Iranica, 27(3), pp. 1-22 (2019). DOI: 10.24200/sci.2019.5152.1123.
24. Mohammadi, S., Cheraghalikhani, A., and Ramezanian, R. "A joint scheduling of production and distribution operations in a flow shop manufacturing system", Scientia Iranica, Transactions E: Industrial Engineering, 25(2), pp. 911-930 (2018).
25. Hemmati Far, M., Haleh, H., and Saghaeia, A. "A flexible cell scheduling problem with automated guided vehicles and robots under energy-conscious policy", Scientia Iranica, Transactions E: Industrial Engineering, 25(1), pp. 339-358 (2018).
26. Ross, P.J., Taguchi Techniques for Quality Engineering, McGraw-Hill, New York, USA (1988).
Scientia Iranica
Volume 28, Issue 1
Transactions on Mechanical Engineering (B)
January and February 2021
Pages 316-325

Files

History

  • Receive Date: 30 May 2019
  • Revise Date: 02 August 2019
  • Accept Date: 12 January 2020

Share

How to cite

Statistics