FABRICATION OF COMPONENTS

1. Formability Effects of Process Parameters on Forming Forces
in Single Point Incremental Forming Process

2. Outline of the Presentation
 ABSTRACT
 INTRODUCTION
 LITERATURE SURVEY
 PROBLEM IDENTIFICATION
 OBJECTIVE
 RESEARCH METHODOLGY
 REFERENCE

3. INTRODUCTION
 Recently, single point incremental forming has caught the attention of automotive and aerospace
industry as an alternative to conventional stamping process as an economical process capable of
manufacturing sheet metal prototypes devoid of expensive dies.
 Single point incremental forming (SPIF) is a new sheet metal forming process with a high potential
economic payoff for rapid prototyping applications and for small quantity production.
 The basic components of the process ; (i) the sheet metal blank, (ii) the blank holder, (iii) the
backing plate and (iv) the rotating single point forming tool. The blank holder is utilized for
clamping and holding the sheet in position during SPIF. The backing plate supports the sheet and its
opening defines the working area of the single point forming tool. The tool is utilized to
progressively shape the sheet into a component and its path is generated by a CNC machining centre.
 During the forming process there is no backup die supporting the back surface of the sheet.

4. OBJECTIVE
 In this proposed work, the study was to ascertain the nature of cutting forces
expected during the single point incremental forming process and is to study the
effect of different process parameters on these forming forces.
 The study proposed guidelines for forming thick sheets and improving production
rate of SPIF process.
 Single point incremental forming (SPIF) is a truly die-less forming process which
is quite suitable for the batch type and prototype production due to economical
tooling cost, shorter lead time and ability to form nonsymmetrical geometries
without using expensive dies for manufacturing complex components of sheet
metal.

5. ABSTRACT
• This study is to optimize the forming parameters such as
forming step depth, tool feed and spindle speed using Single
Point Incremental Forming (SPIF) on
AA4047/AA5052/AA6061 or alloy
• Surface roughness and wall thickness have been considered as
the responses from the inputs and taken into account.
• Comparison of Forming Limit Diagram (FLD) and wall
thickness on the formed components.
• Experiments were validated performing numerical simulation
and the material behaviour has been analyzed.
• The developed twist during forming due to the tool motion,
has been studied.
• Formability of sheet metal by hole flanging has been
discussed.
• A digital based strain measurement was used for evaluation of
the accuracy of FLD and to measure the strains.

6. INTRODUCTION
• SHEET METAL FORMING
– One of the most classical methods of sheet metal working
operations is the forming process.
– Conversion of sheet metal into any desired form without any
crack on the surface.
– The forming can be adjusted by controlling various process
parameters.
– Most of the forming operations are combinations of bending,
stretching, drawing and coining.
– Accuracy depends mainly on various factors like material
behaviour, forming equipment, lubrication used, etc.

7. S.No. Author Title Year of
Publication
Inference
4. B.T.H.T.
Baharudin,
Q.M. Azpen,
Shamsuddin
Sulaima ,
and
F. Mustapha
Experimental
investigation of
forming forces in
frictional stir
incremental forming
of aluminum alloy
AA6061-T6.
2017 In this article, frictional stir-assisted SPIF was
used to deform AA6061-T6 aluminum alloy.
Experimental tests were conducted to measure
the forming forces during this process for the
concerned lightweight material. The influence of
process parameters was investigated, which
included tool rotation speed, feed rate, step size
and tool diameter on the produced forming
forces. A Taguchi technique for the design of
experiment (DOE) and the varying wall angle
conical frustum (VWACF) test was employed in
this study. The results show that the rotation
spindle speed was the most dominant parameter
that affects the forming forces, followed by the
step size, feed rate and tool diameter.
A series of experiments was conducted to
evaluate the impact of rotation speed, feed rate,
step size and tool diameter on the forming forces
during the frictional stir-assisted SPIF.
In the current study, frictional stir-assisted
SPIF was applied for deformation of the
AA6061-T6 aluminum alloy. The aim was to
investigate the impact of rotational tool speed,
feed rate, step size and tool diameter on the
values of the forming forces during the forming
process.

8. Thank You