Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology

Li, Yanle, Lu, Haibo, Daniel, William, J.T and Meehan, Paul A (2015) Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology. International Journal of Advanced Manufacturing Technology, 79 9-12: 2041-2055. doi:10.1007/s00170-015-6986-5


Author Li, Yanle
Lu, Haibo
Daniel, William, J.T
Meehan, Paul A
Title Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology
Journal name International Journal of Advanced Manufacturing Technology   Check publisher's open access policy
ISSN 1433-3015
0268-3768
Publication date 2015-03-14
Year available 2015
Sub-type Article (original research)
DOI 10.1007/s00170-015-6986-5
Volume 79
Issue 9-12
Start page 2041
End page 2055
Total pages 15
Place of publication London, United Kingdom
Publisher Springer UK
Collection year 2016
Language eng
Abstract Incremental sheet forming (ISF) is a promising manufacturing process that features benefits of reduced forming forces, enhanced formability and greater process flexibility. It also has a great potential to achieve economic payoff for rapid prototyping applications and for small quantity production in various applications. However, limited research has been conducted from the sustainability point of view, particularly for energy consumption. More consumed energy will generate more heat and affect tool and product wear. Also, geometric accuracy is still one of the dominant limits for the further development and commercialization of the ISF technology. Therefore, the aim of this study is to investigate how different process parameters affect the consumed energy during the forming process and also find the optimal working condition for lower deformation energy with higher geometric accuracy. A Box-Behnken design of 27 tests for pyramid-forming processes have been performed for a multi-objective optimisation that considers four factors: step down, sheet thickness, tool diameter and wall angle at three levels. The deformation energy during the forming process was calculated based on the measured forming forces. It was found that the deformation energy heavily depends on the sheet thickness because of higher plastic energy required to deform the material. Increasing step-down size within a limited range or decreasing the wall angle is also an effective approach to reduce the deformation energy. Moreover, the effects of various process parameters on the global geometric accuracy have also been investigated. The geometric error has been empirically predicted by quadratic equations giving the influence of the most influential forming parameters. It was concluded that the geometric quality is largely determined by the quadratic effect of wall angle, the linear effect of sheet thickness and the interaction effect of thickness and step down. Finally, the optimal working conditions for both independent and simultaneous minimisation of deformation energy and geometric error during the pyramid-forming process are provided.
Keyword Incremental sheet forming
Box-Behnken design
Response surface methodology
Energy consumption
Geometric accuracy
Optimisation
Q-Index Code C1
Q-Index Status Confirmed Code
Institutional Status UQ

Document type: Journal Article
Sub-type: Article (original research)
Collections: School of Mechanical & Mining Engineering Publications
Official 2016 Collection
 
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