End sem presentation.pptx

1. BITS Pilani
Hyderabad Campus
End Semester Presentation
Semester II(2017-18)
Department of Mechanical Engineering
Candidate Name : G. Praveen Kumar
ID No. : 2016PHXF0420H
Supervisor Name : Dr. K. Suresh
DAC members:
Dr. Pavan Kumar .P
Dr. Nitin .K

2. BITS Pilani
Hyderabad Campus
Experimental investigations and mathematical
modeling of incremental forming processes

3. BITS Pilani, Hyderabad Campus
Contents
 Objectives of the Proposed Research
 Experimental plan
 Results
 Summary of the work
 Publications
1

4. BITS Pilani, Hyderabad Campus
Objectivesoftheproposedresearch
2
1. Analysis of surface roughness in parts formed by incremental forming.
2. Experimental and theoretical studies on formability in incremental
forming.
3. Analysis of form accuracy, spring back and forming forces in
incremental forming process.
4. Experimental investigation in incremental hole flanging process.
5. Finite element (FE) simulations of incremental forming.

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Levels
Parameter Notation Unit Low Middle High
Tool
diameter
A mm 5 10 15
Step depth B mm 0.25 0.75 1.25
Wall angle C Degree 30 50 70
ExperimentalPlan
Table 1. Process parameters and their levels used for the surface finish studies
.
3

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Figure 1. Formed parts with different process parameters
Incrementalformedparts
4

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Results
S.No Tool dia Step depth Wall angle Ra (μm)
1 5 0.25 30 1.54
2 5 0.75 30 2.40
3 5 1.25 30 3.22
4 5 0.25 50 1.17
5 5 0.75 50 3.59
6 5 1.25 50 3.39
7 5 0.25 70 0.83
8 5 0.75 70 3.22
9 5 1.25 70 2.48
10 10 0.25 30 1.69
11 10 0.75 30 2.24
12 10 1.25 30 1.59
13 10 0.25 50 0.88
14 10 0.75 50 2.02
15 10 1.25 50 2.15
16 10 0.25 70 0.67
17 10 0.75 70 1.66
18 10 1.25 70 1.47
19 15 0.25 30 1.15
20 15 0.75 30 1.12
21 15 1.25 30 1.07
22 15 0.25 50 0.70
23 15 0.75 50 0.60
24 15 1.25 50 1.52
25 15 0.25 70 0.72
26 15 0.75 70 2.32
27 15 1.25 70 1.07
Table 2. Experimental results.
5

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0
0.5
1
1.5
2
2.5
3
3.5
5 10 15
Ra
Tool diameter
0.25
0.75
1.25
5 10 15
0.25 1.54 1.6 1.17
0.75 2.4 2.24 1.12
1.25 3.22 1.58 1.06
Fig. 2 Variation of surface finish with tool diameter at 30 deg wall angle
Results
6

9. BITS Pilani, Hyderabad Campus
Results
0
0.5
1
1.5
2
2.5
3
3.5
4
5 10 15
Ra
Tool diameter
0.25
0.75
1.25
5 10 15
0.25 1.15 0.84 0.7
0.75 3.59 2.13 0.64
1.25 3.39 2.15 1.52
Fig. 3 Variation of surface finish with tool diameter at 50 deg wall angle
7

10. BITS Pilani, Hyderabad Campus
Results
0
0.5
1
1.5
2
2.5
3
3.5
5 10 15
Ra
Tool diameter
0.25
0.75
1.25
5 10 15
0.25 0.83 0.67 0.74
0.75 3.22 1.66 2.32
1.25 2.48 1.11 1.07
Fig. 4 Variation of surface finish with tool diameter at 70 deg wall angle
8

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0.25
0.75
1.25
0
0.5
1
1.5
2
2.5
3
3.5
4
5
10
15
5
10
15
5
10
15
30
50
70
Ra (μm)
0.25
0.75
1.25
Results
Fig. 7 The influence of step deapth, wall angle (φ) and tool size up on surface roughness (Ra)

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Length = 12.5 mm Pt = 61.1 µm Scale = 100 µm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-40
-20
0
20
40
Roughness profile, Gaussian Filter, cut-off 0.800 mm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-7.5
-5
-2.5
0
2.5
5
7.5
10
Waviness profile, Gaussian Filter, cut-off 0.800 mm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-40
-20
0
20
40
Roughness profile Waviness profile, Gaussian Filter, cut-off 0.800 mm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-40
-20
0
20
40
10 0.75 30 Ra 2.37 µm
Results
Fig. 5 Typical surface roughness profiles
9

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Results
Roughness profile Waviness profile, Gaussian Filter, cut-off 0.800 mm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-40
-20
0
20
40
5 1.25 30 Ra 3.20 µm
Length = 12.5 mm Pt = 75.3 µm Scale = 100 µm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-40
-20
0
20
40
Roughness profile, Gaussian Filter, cut-off 0.800 mm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-10
-5
0
5
10
15
Waviness profile, Gaussian Filter, cut-off 0.800 mm
0 1 2 3 4 5 6 7 8 9 10 11 12 mm
µm
-40
-20
0
20
40
Fig. 6 Typical surface roughness profiles
10

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Results
10 0.25 30 10 0.75 50 15 0.25 50
5 0.25 50 5 1.25 30 15 0.75 70
Fig. 7 Surface textures of parts formed in incremental forming at 10× magnification
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Objective 1: Experiments have been conducted on Bridgeport
Hardinge three axis CNC milling machine. Surface roughness
values of formed parts was measured using talysurf stylus
instrument.
Summaryofthework
12

16. BITS Pilani, Hyderabad Campus
International Conference:
1. “Experimental studies on incremental hole flanging of steel sheets”, 20th Edition
of International Conference On Advances in materials and processing
technologies, 11 - 14 December 2017. VIT University – Chennai, India.
(Accepted)
2. “Analysis of formability in incremental forming processes”, 7th international
conference on materials processing and characterization 2017, GRIET, March
17-19 2017, Hyderabad, Telangana, India. (Accepted)
Publications
13

17. BITS Pilani
Hyderabad Campus
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