Optimization of Process Parameter During Multi-Point Incremental Forming of AA3003 Alloy Sheets Using Grey Relational Analysis

Single point incremental forming (SPIF) is a die-less forming operation suitable for tailor made parts, low volume manufacturing and prototyping. The method is extensively employed in the aerospace, medical, and automotive fields. The method's main drawback is the extensive processing time compared to the traditional forming method, which can be minimized using a multi-point forming tool. This research concentrates on the significance of input factors like tool feed rate, step depth and speed on formability, surface finish, spring back, wall angle, and forming time during multi-point incremental forming. Three levels of the input parameters were considered and the experimental runs were designed by Taguchi L9 orthogonal array. The conflicting objectives were converted in to single grey relational grade (GRG) and optimized using response surface methodology (RSM). Finally, the output results are validated using a conformation test. Incremental sheet forming is widely used for producing custom made parts and is most suitable manufacturing process in the digital manufacturing industry.