Effect of Process Parameters on Surface Roughness of Square Flange Formed by Single Point Incremental Forming

The metal forming using single point incremental forming technique is carried out without using dedicated punch and die. Research studies show that the principle of single point incremental forming can be applied to hole flanging process. In this work, experiments are performed as per Box-Behnken design to analyze how the spindle speed, feed rate, and step depth affect the surface roughness of the square flange by single point incremental forming. The surface roughness of inner surface of the formed square flange is considered as a response parameter. The results are analyzed by plotting the plots of main effects and by performing ANOVA. The step depth has a major effect on the surface finish and the highest surface finish was obtained for step depth of 0.1 mm.