Studies on experimental and numerical analysis of incremental forming on AA5052 alloy

Abstract

Forming Limit Diagram FLD is the most prominent representation for formability in sheet metal forming processes Many sheet metal forming techniques are used for determining the formability of sheet metals One of the simplest emerging methods is the Single Point Incremental Forming SPIF method where forming occurs in the absence of dedicated dies Any external complicated shaped can be formed using a Computer Numerical Controlled CNC machine and a hemispherical round tool This process can also be used for small batch applications due to reduced manufacturing costsAA5052 alloy has been widely used a major structural member where good mechanical and corrosion resistive properties are required However this material has less formability when it has to be processed in as it is condition In view of this there is need for a detailed investigation to improve formability by examining and optimizing the process parameters and evaluating the FLD The main objective of this study is to optimize the forming parameters such as forming step depth feed rate and spindle speed using SPIF on AA5052 alloy processed as it is condition The obtained output such as surface roughness and wall thickness have been considered as the responses from the inputs and taken into account Response Surface Methodology RSM with Central Composite Design CCD has been used to study the effect of input parameters forming step depth feed rate and spindle speed with response to the outputs surface roughness and wall thickness newline