Performance Analysis of Multi-Point Incremental Forming Tool using Martensitic AISI 420 Sheet Metals

Incremental Sheet metal Forming (ISF) Process is a suitable process which helps to produce various parts used in automotive sector by rapid prototyping. This method of producing a prototype helps industry in reducing the production cost. In ISF process, a final product is evolved through local deformation of the sheet metal made by the tool. Usually better formability is obtained when the tool makes a better contact with the sheet metal throughout the process. Improved formability elevates dimensional accuracy of the product, thus increases the market value of the product. A new tool with multiple ball ends capable of making multiple mating points over sheet metal was used in this research to enhance the efficiency of formability and surface finish. Ability of the new Multi-Point Incremental Forming Tool (MPIF) was investigated and compared to the existing Single Point Forming Tool (SPIF) based on the formability and surface finish. Forming Limit Diagram (FLD), Strain Distribution (SD) and Scanning Electron Microscope (SEM) were used to examine the formability of the sheet metal. The SEM & 3D-Surface roughness profilometer were used to observe the sheet metals surface finish. In addition to these experimental techniques a simulation results were also used to predict the stress and strain rate during forming process. The experimentation and simulation outcome shows that the MPIF provides superior formability and surface finish

Formability of HSLA and EDDQ steels of tube products of India

141-150In this work, the formability of HSLA (micro alloyed steel of 1.6 mm thickness) and EDDQ (1.2 mm thickness) steels have been studied and the suitability of HSLA and EDDQ steels for forming applications have been examined. The experimental work on microstructural aspects, tensile properties and formability parameters were carried out for both the steel sheet metals. The forming limit diagram for EDDQ and HSLA steels have been experimentally evaluated. A detailed analysis of the strain distribution profiles obtained from experiment has been attempted. The fracture surfaces of the formed samples have been observed using scanning electron microscopy with a view to obtain a correlation between fracture behaviour and formability of the sheet metals. The EDDQ steel has been found to possess good drawability and stretchability, whereas the HSLA steel has been found to possess limited drawability and stretchability

Optimization of machining parameters on microdrilling of CFRP composites by Taguchi based desirability function analysis

331-338Microdrilling of CFRP composite materials is a complex process due to its properties and defects occur during the machining process. Optimization of process parameters is important to achieve the desired responses. This paper implies a new approach for optimizing the process parameters on drilling carbon fibre reinforced polymer (CFRP) composites. Optimization of process parameters is done by a method named as desirability function analysis (DFA), which is very useful tool to optimize multiple response problems. In microdrilling process, the feed rate and spindle speed and air pressure are selected as input parameter. Circularity and Feret’s diameter are taken as output parameters.The 0.5 mm solid carbide drill is chosen for microdrilling process. Analysis of variance (ANOVA) is adapted to investigate the performance characteristics of machining parameters. The confirmation tests are conducted to validate the test result.The analysis reveals out that hole quality is mostly influenced by air pressure

Optimization of machining parameters of EDM while machining Inconel 718 for form tolerance and orientation tolerance

391-397This paper demonstrates the effectiveness of optimizing multiple characteristics of electrical discharge machining (EDM) of Inconel 718 using copper electrodes having different shapes via Taguchi method-based Grey analysis. The modified algorithm adopted here is used successfully for both detraining the optimum settings of machining parameters and for combining multiple quality characteristic into one numerical value called Grey relational grade or rank. The essential parameters like peak current, pulse on time and pulse off time are chosen to conduct the experiments on multiple characteristics namely material removal rate (MRR), electrode wear rate (EWR), form tolerance namely straightness and orientation tolerance like perpendicularity and angularity. Then, ANOVA is used to find out the parameter which significantly affects the other parameters. The experimental results have shown that the machining performance on multiple characteristics in the EDM process is improved effectively through this approach

Form tolerances investigation in EDM process for super alloys using multiple holes electrodes

200-204The present work focuses on experimental quality analysis of electrical discharge machining (EDM) of two super alloys namely Inconel 718 and Inconel 625 with different diameter of hole of multiple holes copper electrodes. The diameter of hole of multiple holes in electrode, pulse current and (Ton) pulse on time have been chosen as process parameters to conduct the experiment trails. The MRR, EWR and form tolerance have been considered as output responses

EXPERIMENTAL INVESTIGATION ON ELECTRICAL DISCHARGE MACHINING OF TITANIUM ALLOY USING COPPER, BRASS AND ALUMINUM ELECTRODES

In the present study, an evaluation has been done on Material Removal Rate (MRR), Surface Roughness (SR) and Electrode Wear Rate (EWR) during Electrical Discharge Machining (EDM) of titanium alloy using copper, brass and aluminum electrodes. Analyzing previous work in this field, it is found that electrode wear and material removal rate increases with an increase current. It is also found that the electrode wear ratio increases with an increase in current. The higher wear ratio is found during machining of titanium alloy using a brass electrode. An attempt has been made to correlate the thermal conductivity and melting point of electrode with the MRR and electrode wear. The MRR is found to be high while machining titanium alloy using brass electrode. During machining of titanium alloy using copper electrodes, a comparatively smaller quantity of heat is absorbed by the work material due to low thermal conductivity. Due to the above reason, the MRR becomes very low. Duringmachining of titanium alloy using aluminium electrodes, the material removal rate and electrode wear rate are only average value while machining of titanium alloy using brass and copper electrodes

Modelling the Forming Limit Diagram for Aluminium Alloy Sheets using ANN and ANFIS

In this work, it is planned to model the formability of various grades of aluminium sheet metals using ANN and optimization is done using ANFIS. Formability test is performed on aluminium sheet metals Al5052, Al6061 and Al8011 with thickness 0.8 mm, 1 mm and 1.2 mm. Forming limit diagrams are constructed using strain values obtained from the test. Tensile tests are conducted on the sheet samples and the important mechanical properties which affect the formability are measured and calculated. Using the forming limit strains at different states namely tension-tension, plane strain and tension-compression, modeling is done using ANN and optimization is performed using ANFIS. The architecture 7–14-14–9 is found to be the optimum and it is used in ANN modeling. Using the strain values predicted by ANN, FLD curves are constructed. The predicted strain values are compared with experimental strain values. Further optimized strain values are predicted using ANFIS. This work reveals that experimental FLD, ANN predicted FLD and ANFIS predicted FLD are in good agreement

Forming Limit Diagram, Void Analysis, Strain Distribution and Surface Roughness for SS430 Sheets During Multipoint Incremental Forming

Single point incremental forming process is a most economical Die-less forming process. The major constraint of it is that it is a time consuming process. In this work, a new attempt was made in incremental forming process using Multipoint tool for SS430 sheets to increase the formability and to reduce forming time. Fractography analysis was made to study the size of voids that were formed during fracture. The forming limit diagrams were drawn and compared for single point incremental forming and the multipoint incremental forming of SS430 sheet. It was proved that the formability of SS430 sheet in the multipoint forming was better than the formability of that in single point forming and the time consumed was reduced. The strain distribution in both processes had also been studied along with surface roughness