Improvement of Surface Roughness in Single Point Incremental Forming Process by the Implementation of Controlled Vibration
Engineering and Technology Journal,
2022, Volume 40, Issue 1, Pages 217-225
AbstractVibration implementation that assists metal forming has many advantages, such as enhancement of surface equality, reducing the forming force and decreasing the stresses. The technology of single-point incremental forming with all the above-mentioned advantages has been performed with the vibration. This paper focuses on the average surface roughness (Ra) improvement of the final product by using the vibration. The average roughness was found to be affected by vibration of the sheet metal. The combination of vibration produced a better surface quality of the forming shape by using an active damper to control the vibration. For determining the damping ratio, which gives the necessary roughness, an artificial neural network (ANN) was created based on experimental results. A feed forward neural network with Liebenberg–Marquardt back propagation algorithm was utilized for building the artificial neural network model (3-n-1). Confirmation runs were conducted for verifying the agreement between the predicted results of ANN with those of the experimental outcomes. As a result, the product surface quality is increased where the surface roughness was reduced by (18%) from the surface roughness without vibration. The best reduction rate was in the axial forming force at (100 Hz) frequency, where the reduction rate was about (11.64%) from the force without vibration.
- Vibration implementation assists metal forming enhancement surface quality.
- Effect of low frequency vibration on forming force.
- Active damper used to control the vibration.
 D. Xu, R. Malhotra, N. V. Reddy, J. Chen, and J. Cao, Analytical prediction of stepped feature generation in multi-pass single point incremental forming, Journal of Manufacturing Processes, 14 (2012) 487–494.
 A. Kumar, V. Gulati, P. Kumar, Investigation of Surface Roughness in Incremental Sheet Forming Procedia Computer Science, 133 (2018) 1014–1020.
 M. Vahdati, R. A. Mahdavinejad, S. Amini, M. Moradi,Statistical Analysis and Optimization of Factors Affecting the Surface Roughness in the UVaSPIF Process Using Response Surface Methodology,Journal of Advanced Materials and Processing, 3 (2015) 15-28.
 M. Vahdati, R. Mahdavinejad and S. Amini, Investigation of the ultrasonic vibration effect in incremental sheet metal forming process, Proc. IMechE, Part B: J Engineering Manufacture, 1–12 IMechE, (2015).
 V. Mugendiran, A. Gnanavelbabu, R. Ramadoss, Parameter optimization for surface roughness and wall thickness on AA5052 Aluminium alloy by incremental forming using response surface methodology, Procedia Engineering, 97 (2014) 1991 – 2000.
 S. Kurra, N. H. Rahman, S. P. Regalla, A. K. Gupta, Modeling and optimization of surface roughness in single point incremental forming process, J. of Material Research and Technology, 4 (2015) 304-313.
 E. Hagan and J. Jeswiet, Analysis of surface roughness for parts formed by computer numerical controlled incremental forming, Proc. Instn Mech. Engrs., 218 (2004) Part B: J. Engineering Manufacture.
 V. Mugendiran, A. Gnanavelbabu, R. Ramadoss, Parameter optimization for surface roughness and wall thickness on AA5052 aluminium alloy by incremental forming using response surface methodology, Procedia Eng. 97 (2014) 1991–2000.
 S.P. Shanmuganatan, V.S. Senthil Kumar, Experimental investigation and finite element modeling on profile forming of conical component using Al 3003(O) alloy, Mater. Des. 36 (2012) 564–569.
 A. Mulay, B. S. Ben, S. Ismail, A. Kocanda, Prediction of average surface roughness and formability in single point incremental forming using artificial neural network, Archives of Civil and Mechanical Engineering, 19 (2019) 1135-1149.
- Article View: 62
- PDF Download: 42