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Abstract
New experimental data is presented on Forming Limits in Single Point Incremental Forming (SPIF),
which is a sheet metal forming process which does not require dies. A Box-Behnken Design of
Experiment is used to develop the experimental plan and analyze data. In former work, the most
critical factors affecting Single Point Incremental Forming were found to be material type, material
thickness, formed shape, tool size, and incremental step size. In this experimental work, new
results are presented as graphical response surfaces which show the forming limit for all the critical
factors listed previously. In addition, forming limits are presented in terms of Forming Limit
Diagrams.
Keywords:
Forming; Sheet metal; Incremental Forming
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The tensile test is often used to compare the formability of
various materials. For this work the Ultimate Tensile
Strength (UTS) for AA6451 is 340 MPa and the maximum
strain is 0.170, the average effective strain is 0.495. The
UTS and maximum strain for AA5182 and AA5754 are
155 MPa, 105 MPa and 0.230, 0.240, respectively; while
the average effective strains are 0.975 and 1.10.
450
6451 C 0.9mm
400
6451 A 0.9mm 6451 1.5mm
350 5182 0.9mm
5182 1.15mm
300
1.4
y = -2.8349x2 - 0.7927x + 1.257 6451
1.2 5182
1 5754
Major Strain
0.8
0.6
y = -12.255x2 + 1.5155x + 0.9508
0.4
0.2
2
y = -5.246x + 0.1012x + 0.491
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
Minor Strain
Figure 5. Forming Limit Diagram for Material Type Figure 7. RS Avg.CH – Material Type and Thickness
Figure 6 depicts the stress-strain diagram for the Figure 8 shows the same “U” when comparing the affect
materials used in the experiments. The AA6451 of material type on averageCH with the AA6451 having the
aluminum, which incurred the lowest strains in the
lowestCH. When comparing tool sizes to the averageCH,
experiments, had the lowest strains and highest stresses
the AA5754 alloy seems to have no affect as the contour
in tensile tests. The curves on the stress-strain diagram
are the average stress and strains of the tensile tests
completed.
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is flat; AA6451 the largest tool size has the lowestCH and 3 SUMMARY
the other tool sizes have no effect onCH. In AA5182 alloy The objectives of this research are to develop the best
the averageCH increases for decreasing tool size. way to accurately define the forming limits of SPIF. A
Box-Behnken experimental design is used to determine
the affect of material type, material thickness, shape, step
size and tool size on the maximum forming angle,
effective strain, major and minor strains. The
experimental design allows for the solving of these five
forming factors at three levels in forty-six experimental
runs; 500 samples.
Material type has the greatest effect on formability, as
expected; followed by the shape; as shown by the
response curves in both maximum forming angle and
effective strain. Tensile tests can be used to determine
whether a material will be formable, the lower the UTS the
greater the formability.
A set of Response Surfaces (RS) are developed to assist
designers in understanding when SPIF is a viable
Figure 8. RS Avg.CH – Tool Size and Material process. This research gives great detail on some specific
Figure 9 has the shape common to the other graphs due aluminum alloys. If another alloy is of interest, only eight
to material type. The AA5754 has decreasingCH for experiments are required to update these response
decreasing step sizes, AA5182 has decreasingCH for surfaces to reflect the new alloy. This shortens the
experimentation time needed to study specific alloys.
increasing step sizes; the AA6451 has the largestCH for
This is a new process a designer can use to determine if
the 0.005 step size.
SPIF process is applicable.
This present work is summary of how FLDs in SPIF are
developed and present the methodology for developing
FLDs. Further work on FLDs for SPIF will be forthcoming
by the authors.
4 ACKNOWLEDGEMENTS
The authors thank Queen’s University Department of
Mechanical and Materials Engineering, the Natural
Science and Engineering Research Council of Canada,
Novelis Global Technology Centre and IRDI for their
support in this research. The authors would also like to
thank Dr J. McLellan for all his assistance with the
statistics involved in this research.
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