Engineering and Technology Journal

Investigating the Impact of Process Parameters on Thinning and Formability in Aluminum Alloy AA 1050 Incremental Sheet Metal Forming

Document Type : Research Paper

Authors

1 Production Engineering and Metallurgy Dept., University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.

2 Mechatronics Engineering Dept., Al-Khwarizmi College of Engineering, University of Baghdad, Baghdad, 10071 Iraq.

Abstract

ISMF is a potential manufacturing technology that uses progressive deformation to create complicated shapes. ISMF produces sheet metal consecutively using targeted tool movement. This innovative method increases component precision, material waste reduction, and design flexibility. A tool is moved along a set path over a flat metal sheet while twisting forces are applied to get the needed shape. SPIF could be used in the medical equipment, aerospace, automotive, and building industries, but it is only profitable in certain situations because it is slower than other sheet-forming methods. SPIF-based die-less making makes it easier to shape. To make cone-shaped structures with SPIF, the spindle speed (1000, 1500, and 2000 RPM), feed rate (200, 400, and 600 mm/min), tool width (8, 10, and 12 mm), and step-down (0.2, 0.4, and 0.6 mm) at the specimen interface were all changed. For aluminum alloy AA 5010, the maximum thinning (mm) and formability (%) were the important mechanical qualities. The L9 orthogonal array was used for a complete look at these qualities. Making high-quality cones using a computer numerically controlled machine was the aim of this research. (CNC) machine. The important factors affecting engineering and forming quality were studied using the Taguchi and analysis of variance methods. The most influential factor on maximum thinning was the rotational speed followed by the feeding, which is inversely proportional to it. In contrast, the most effective factor on the formability is the feeding followed by the rotational speed, which is directly proportional to it. It was discovered that a spindle speed of 1500 revolutions per minute (RPM), a feed rate of 200 millimeters per minute (mm/min), a tool diameter of 10 millimeters (mm), and a step down of 0.4 millimeters provide the least amount of maximum thinning (mm) and formability (percent).

Graphical Abstract

Highlights

  • Nine specimens were fabricated with different processing parameters using a CNC machine
  • Investigating the influence of Spindle speed, Feed, tool diameter, and step down on the maximum thinning and formability
  • The dominant factor affecting Maximum thinning is the spindle speed large effect

Keywords

Main Subjects

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Engineering and Technology Journal
Volume 41, Issue 12
Production & Metallurgy Engineering
18 articles
December 2023
Page 1653-1659
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