Multi-objective Optimization of Single Point Incremental Forming

One of the emerging unconventional forming techniques which shows considerable promise in meeting the demand in the digital manufacturing world is the incremental sheet metal forming technique. In this process, a special type of tool is made which is then attached to the CNC machine. The workpiece is fixed to a fixture, and the tool moves over the workpiece along a specified tool path. AA6061-T6 aluminum alloy has nearly the same tensile strength as stainless steel but is much lighter, therefore making itself prominent in the aerospace and automotive industry. In this study, 5 important factors influencing the output responses in incremental forming are selected according to previous literature. Taguchi DOE was conducted to get an L18 OA experiment design and the optimum parameters for better formability, forming depth, and forming time was determined using Taguchi-DEAR method. The optimum input variables combination is found to be 300 mm/min feed, 500 RPM speed, 0.4 mm step depth along with a 12 mm tool with oil lubrication.