Influence of process parameters on surface roughness in single point incremental forming using dummy sheet

Abstract

Single point incremental sheet forming (SPIF) is an advanced sheet metal forming process. It is flexible and does not require dedicated punch and die set-up for forming operation. But due to its high surface roughness, it is still not so popular in sheet metal industries. But when SPIF is performed with dummy sheet at the top of target sheet, then this limitation is eliminated to some extent. In the present paper, research work involved in experimental study on influence of process parameters on surface roughness in SPIF using dummy sheet is described. Five process parameters namely dummy sheet thickness, tool size, step size, wall angle and feed rate are considered in the present study. From the analysis of variance (ANOVA), it is found that parameters namely dummy sheet thickness, tool size, step size, and wall angle are significant and feed rate is insignificant. The surface roughness decreases with increase in wall angle, dummy sheet thickness and tool size while increases with the increases in step size.