Effect of the Single-Point Incremental Forming Process Parameters on the Surface Roughness of Aluminum Alloy Al 2024-O Draw Pieces

Abstract

The incremental sheet metal forming process is a highly adaptable manufacturing process for producing three-dimensional products without the need for specialized tool typically required in traditional forming processes. This innovative process finds extensive applications in various industries, including aerospace, automobile, and other industrial applications. This study explores the application of the single-point incremental forming (SPIF) process to manufacture truncated pyramids while investigating the impact of specific process parameters on surface rough-ness. In this study, three parameters wall angle, sheet thickness, and step depth were examined, each at three different levels. A full factorial design (L27) was used to design the experimental work and statistical analysis utilizing Analysis of Variance (ANOVA) was utilized to analyze the collected data and predict the impact of single-point incremental forming process parameters on surface roughness. The tool geometry was a hemispherical end tool with a diameter of (8 mm) and the sheet material was aluminum alloy (Al 2024-O). The computer numerical control (CNC) milling machine was used to move the tool. The optimal average roughness (Ra) value was achieved with a wall angle of 60°, a sheet thickness of 2 mm, and a step depth of 0.2 mm.