Investigation of Step-Size Application Directions in Incremental Sheet Forming Process
摘要
The incremental sheet forming (ISF) process is an advanced manufacturing process capable of producing a variety of sheet metal components without using complex dies and tools. This process involves deforming a sheet along a predetermined tool path using CNC machine. Most of the published literature on toolpath optimization focuses on step-size optimization only. However, the application direction of the step size is an important parameter in the development of the toolpath. Owing to this inspiration, this experimental investigation intended to analyze the toolpath with a focus on the direction of step-size application. To conduct the experiments, a full-factorial design was planned using Minitab. The design included one categorical factor: step-size application direction (horizontal, vertical, and inclined) with three levels, and two numeric factors: step size (0.25 and 0.75 mm) with two levels, and wall angles (31°, 45°, and 59°) with three levels. Average sheet thickness, average internal surface roughness, and forming time are the process responses. After the accomplishment of the experiments, it was revealed that step-size application direction has a considerable impact on surface roughness and forming time, although its impact on the average sheet thickness is negligible. The wall angle significantly influences the average sheet thickness and surface roughness (Ra). An inverse association between surface roughness and wall angle is observed.