Effect of operational parameters on incremental forming of low-alloy sheet metals and its optimisation

ABSTRACT

Incremental forming is a method with great forming potential. With this method, especially Low-Alloy Sheet Metals prototypes can be produced. Low-Alloy Sheet DC01, one of the metals, is widely used in the machinery industry. In this study,manufacturability of conical frustum part with circular generatrix form was investigated by “single point incremental forming” method. DC01 sheet was used as the test material. Signal/Noise analysis was performed to investigate the effects of experimental parameters. Later, gray relationship analysis performed. The optimal parameters for the incremental formability of the variable wall angle conical frustum shaped DC01 sheet metal were determined. As the increment and the feedrate decreased, it was observed that both surface roughness and forming force decreased. Surface roughness and forming force are both observed to increase with the growth of the forming tool diameter.

KEYWORDS:

• Incremental forming
• gray relationship
• forming force
• surface roughness
• formability